In detail: do-it-yourself repair of the cylinder head of a VAZ 2109 from a real master for the site my.housecope.com.
Burning out the gasket under the cylinder head on VAZ 2109-2108 cars is the most common reason why you have to remove the head from the engine, and, accordingly, with further repair, or rather, replacing the gasket. If you do not notice this problem in time, then this can lead to rather sad consequences, since the engine can overheat and even jam.
The procedure itself for removing the cylinder head and replacing its gasket is not difficult, but at the same time it requires certain technical skills and a small number of tools, the list of which is given below:
Allen key or similar bit with adapter for use with a crank
Torque wrench - in this case, I used the Ombra model with a range of 10 to 110 Nm, which is sufficient
Flat screwdriver
Extension
Gasket Remover
Of course, it will first be necessary to carry out some preparatory procedures, without which it will be impossible to remove the head.
First, you need to remove the air filter housing
Then disconnect all fuel hoses and power wires from the carburetor or injector (depending on the type of engine)
Drain the coolant completely from the system
Disconnect the pants from the exhaust manifold
Remove the distributor, although this is not a prerequisite - it will be enough to disconnect the high-voltage wires
Unscrew and remove the valve cover
In general, it is necessary to free the head from all that is superfluous so that unnecessary problems do not arise during dismantling. Of course, if you decide to completely replace it or repair it, then you will have to perform more operations, and remove the carburetor and collectors. Well, if it's only a gasket, then you can get by with a minimum of actions.
Video (click to play).
To unscrew the cylinder head on a VAZ 2109-2108, it is necessary to use a powerful knob and a hexagon, since the bolts attaching it to the cylinder block are wrapped with a large torque. In total, you will have to unscrew 10 bolts, which are shown in the photo below:
As a lever, you can use a nozzle in the form of an ordinary metal pipe:
Then you can remove the bolts together with the washers, as shown in the picture:
And now you can gently lift the cylinder head of the VAZ 2109-2108 up, removing it from the engine block:
Then the following picture opens to us:
The gasket can remain both on the surface of the head and adhere to the block itself. You can try to remove it by hand without using any tools, and if it does not work, you can gently pry it off with a flat screwdriver without damaging the surface of the part.
Examine carefully the surface of the cylinder head and if there are pronounced traces of corrosion on it, especially in the immediate vicinity of the coolant channels, in this case it is necessary to repair it: milling, grinding, etc. If everything is normal, then we remove traces of the old gasket using special means:
We are waiting for a few minutes until the whole thing turns off and we remove the residues that did not succumb to chemistry, if any, with a razor blade. Then we wipe everything dry and you can even degrease it so that no foreign traces remain on the surface:
The engine block also needs to be cleaned and then replaced with a new gasket. It is important that the holes in the gasket align with the guides that are located at the corners of the block:
Now you can carefully install the cylinder head in its place, making sure that at this moment the gasket does not move out and does not move to the side. Of course, the guides fix it, but you still need to be extremely careful.
Next, we need a torque wrench, since the bolts will have to be tightened with a certain moment of force. It is also worth keeping in mind that the tightening order must be followed. The diagram below shows in what sequence to tighten:
Now with regard to the force with which it is necessary to tighten the bolts. This should be done in 4 steps:
First with a torque of 20 Nm
Second reception with a torque of 75-85 Nm
Tighten each bolt 90 degrees more.
Finally, we wrap it 90 degrees.
It remains after that to install all the equipment removed from the car, fill in coolant, connect all sensors, wires and hoses and check the work done. Usually, everything becomes visible immediately after the antifreeze is poured. If wet marks appear at the junction of the head and the block, then you can remove everything back and do all the work again! But I hope that this will not happen in your practice! Happy renovation!
The design of any internal combustion engine, including VAZ 2109 8-valve engines, provides for the following components:
The combustion chamber;
Valve mechanism;
Cast lines;
Exhaust manifolds;
Intake manifolds.
If you perform boring and correct the current state of the manifold and cylinder head channels, you can increase the cylinder filling ratio, which leads to an increase in engine output and power. It is not uncommon for the revision to be performed as the final stage to increase the volume of the internal combustion engine.
Modification of the cylinder head is carried out to achieve the following goals:
Increase the diameter slightly;
Remove defective casting areas;
Correct fillet radii;
Polish the channels.
The geometry of the collectors, together with the cylinder head lines, changes during the revision process. If the work is done incorrectly, you can not only fail to achieve the desired increase in power, but also lose the efficiency of the motor, lead to its rapid wear and tear.
To complete the boring procedure for the cylinder head channels, you will need:
Ball cutter corresponding to the required bore diameter (29, 31, 32 mm);
Sandpaper;
Cones;
Drill;
Calipers;
Smaller hose than bore.
VIDEO To modify the collectors, it is necessary to complete two main stages of work.
Obtain the required channel diameter by milling the collectors
Polish the tract with special tools and devices. To do this, you need to attach medium-grain sandpaper to the hose, and attach the hose to the drill. Due to the rotation of the nozzle inside the bore, the desired effect is achieved
When performing this operation, the most important thing is to maintain the standard location of the axis of the channels and the shape of the section of the flow path.
When modifying collectors, there are a few important rules to follow.
Before starting to bore the cylinder head manifold, be sure to accurately determine the location of the manifolds in relation to the cylinder head. To do this, you need to install a pair of pins.
The diameter of the opening of the inlet pipeline can be made less by 1-1.5 millimeters than the diameter of the counter windows in the head. Largely because of this, many owners of the VAZ 2109 refuse to bore the collectors.
The exhaust manifold openings in diameter can be equal to or larger than the diameter of the cylinder head mating paths by 1-1.5 millimeters.
VIDEO
Before you start creating the new geometry for the inlet and outlet ports, remember that the boring results must be consistent with the manifolds you have already machined.
To comply with this condition, it is necessary to dock the pipeline with the cylinder head and set the required geometry by boring on the traces obtained. To obtain a clear mark, use solid oil or plasticine, which is used to process the end of the cylinder head.
The boring of the cylinder head channels should be aimed at obtaining the following diameters.
Channel diameter
The path in the block head is processed in accordance with the following sequence:
It is bored with a milling cutter from the manifold side to the valve sleeve;
Boring is carried out from the side of the combustion chamber. Make sure new valve seats are in place;
Boring geometry using cones of various configurations;
Channel grinding.
Before starting to work on processing the inlet and outlet channels of the cylinder head, pay attention to several important recommendations of specialists:
Additionally, it is not necessary to process, refine the inner surfaces of the inlet channels with sandpaper. Defects on the surface obtained as a result of milling will contribute to the accumulation of drops of gasoline and its evaporation;
When machining the intake port of the fourth cylinder, you will definitely open the channel of the oil system. It will be necessary to install a sleeve turned in accordance with the dimensions;
When modifying the channels, pay close attention to the observance of the diameters. Having made the holes larger than the prescribed size, you run the risk of opening the cooling jacket, which runs next to it. If you do this, your cylinder head will be unusable.
It is imperative to install the bushing in the quarter inlet. Otherwise, you will leave one-on-one thin aluminum wall with oil pressure when the engine is running. A breakthrough of such a wall will be inevitable.
VIDEO
At the final stage of the cylinder head revision, you will need to install a new gasket on the end face of the block head and modify it in accordance with the boring.
Be sure to rework the chamfers and valve seats.
Modification of the block head is a rather complicated, time-consuming process that will require increased concentration and caution in your actions. In this regard, we recommend that you contact professionals, or do such work with your own hands, having received the necessary knowledge in advance.
According to the many years of experience of various motorists, replacing the cylinder head of a VAZ 2109 is most often associated with problems arising from a gasket. But there may be others that can lead to overheating of the engine or even to its seizure.
Repair and revision of the cylinder head on a VAZ 2109 is within the power of any driver, but special tools and a little knowledge of the principle of operation of this unit are required. Recently, tuning of this unit has become more and more popular, thanks to which the power of the car rises. You can do it yourself if you have experience in such work. Working with valves and cylinders requires special knowledge and skills.
The cylinder head VAZ 2109 is a special unit, the main purpose of which is to close the cylinders. It is attached directly to the block itself with special bolts. The cylinder head is important in that it is a direct participant in numerous processes during engine operation. The cylinder head of the power units of cars produced today are distinguished by a rather complex device and are assembled from a significant number of parts.
It may be necessary to replace or repair the cylinder head if you begin to notice that the fuel consumption has increased or the power of the power plant has decreased.
Also, improper assembly and installation of valves and cylinders can lead to malfunctions in the cylinder head system.
If you constantly fill your car with low quality gasoline, then do not be surprised that over time this system will begin to malfunction and need to be repaired.
A crack that has appeared in the block cannot be repaired in any other way than by completely replacing this element.
A symptom indicating problems in the cylinder head may be white smoke coming from the exhaust pipe, caused by the ingress of antifreeze into the engine cylinders.
If oil spots appear on the surface of the coolant in the reservoir, this also indicates that the unit needs repair.This is due to the fact that the oil in one way or another began to get to where it should not be.
Uncommon, but sometimes exhaust gases begin to break through the gasket. There is no other choice here than dismantling the head and replacing the gasket.
Removing the head may be necessary in case of tuning the VAZ 2109, revision, problems with plugs, pulling bolts or cylinder bores.
As we already said, the replacement process is simple, but if you decide to tackle it for the first time, it is better to invite someone with experience in this matter to help. You may also need help if you decide to improve the characteristics of the VAZ 2109 engine by tuning it, using channel boring. Replacing the plugs also requires additional assistance. In this case, certain skills are required to remove old plugs and correctly install new ones.
crank;
screwdriver.
Before proceeding with the removal and repair of the VAZ 2109 cylinder head, it is necessary to follow the order to perform some preparatory work.
The first step is to remove the body of the air purifier.
Disconnect the hoses and wires from the carburetor or injector.
Next, you need to disconnect the pants from the manifold.
We remove the distributor.
We unscrew the valve cover.
We remove the carburetor and collectors.
To unscrew the head bolts on the VAZ 2109, most likely, you will need a gate and a hexagon, because the bolts are tightened with decent effort.
We remove the cylinder head VAZ 2109 from the power unit.
Remove the gasket.
Also, if necessary, we carry out repairs or revision of the engine block assemblies.
Qualified tuning, revision and tuning of the VAZ 2109 head will help to fully reveal the capabilities of your power unit. You've probably heard a lot about this, read or even watched videos on the Internet. Tuning typically bores and smoothes the channels to reduce power-reducing turbulence. The valves are changed to enlarged ones and rubbed against the seats. Also, tuning may involve replacing the standard valve guides with bronze ones.
Lapping control is carried out as follows:
the head in the assembled state lies on its side;
liquid is poured into the collector holes (ordinary water can be used).
If the liquid does not flow through the valves, then this means that the work is done efficiently and the valves are lapped correctly. After all the faults have been eliminated, you can start installing the head.
Start assembly by installing a new gasket. Attention! The holes in the gasket must be sure to coincide with the guides that are located in the corners of the block.
The head must be installed carefully, do not move the gasket from its place at this moment.
We insert the bolts in their places and proceed to tightening with a torque wrench.
Further, in the reverse order, we install the dismantled equipment, injector or carburetor. Filled with fresh coolant. Wires and hoses are connected.
Attention! This operation requires some knowledge and skills. Therefore, before performing it, you should know that the bolts need to be tightened according to a certain pattern and with a certain effort. It will be useful to familiarize yourself with additional material on this topic and watch video instructions.
As you can see, there are certain difficulties in revising the VAZ 2109, tuning, replacing plugs and assembling. But if you learn how to do these jobs yourself, calculate how much money you can save.
In this video, the wizard will show you how to correctly and quickly remove the cylinder head on a VAZ 21099 with your own hands. On a VAZ 2109 car, the head is removed in the same way.
installation of new brake cylinders;
repair of shock absorber struts;
valve adjustment;
ignition setting.
replacement of the fuel pump;
speedometer adjustment.
body work;
salon service.
Many of the listed works are quite possible to do without the help of masters. Do-it-yourself repairs will help save a lot of money.
The engine of the VAZ 2109 car together with the gearbox represent one block, which is attached to three elastic rubber-metal supports located in the area of the engine compartment. A motorist can detect some of the faults on his own. No special diagnostics are required.
If an early ignition is installed on the car or the oil pressure indicator constantly lights up, and a characteristic metallic knock is heard, it means that the crankshaft bearings are out of order.
If the connecting rod bearings knock, it means that there is a large gap in the connecting rod bearings.
The beating of the piston in the cylinder is characterized by a strong knock. Replacement of rings and piston group is required.
VIDEO
The knock of the valves indicates an incorrect adjustment of the clearance or a failed valve spring. A visual inspection is required to determine which part needs replacement.
If low oil pressure is detected when the engine is well warmed up and is idling, then foreign bodies have got under the valve. This is possible if not very good oil was filled.
Excessive oil pressure indicates that the pressure reducing valve is stuck. A very stiff spring may have been installed. The problem will disappear after replacing the defective parts.
Increased oil consumption is usually the result of a failure:
piston rings;
seals;
valves;
guide bushings;
slinger caps.
All of the above malfunctions require repair. For some, periodic preventive maintenance will be enough, while others can only be corrected with a major overhaul. Also, in order for all parts and assemblies to work normally, it is required to maintain the car all the time.
If such work is carried out constantly, then major repairs will not be needed, and the service life will increase by several years. Periodic maintenance of the VAZ 2109 car.
Should be carried out at the beginning of summer and before the onset of cold weather.
The oil should be changed every 15,000 km. The oil purification filter is also changing.
A new fuel filter is installed after 30,000 km.
The brake pads must always be in good condition. Large wear is not allowed.
The running gear should be checked after 10,000 km.
The timing belt changes after 60,000 km.
New candles are installed after 30,000 km.
All of these processes will ensure that the engine runs smoothly without sudden repairs. If, nevertheless, serious breakdowns occur, you will need the help of experienced professionals. Overhaul can be caused by:
unstable motor operation;
extraneous sounds;
strong knocking;
high oil consumption;
increased gas mileage;
drop in power;
coking.
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The reason for this is mainly the poor quality of the gasoline. The type of oil also affects. If different oils were poured, carbon deposits began to appear in the combustion chamber. Long-term work in such conditions causes the appearance of carbonaceous deposits. Carbon deposits appear on the valves, the piston rings cannot move. This phenomenon is called “ring occurrence”. As a result, the walls of the combustion chamber become thicker, and the heat sink works worse.
The phenomenon of carbonization can also be associated with driving on a poorly warmed-up engine. Low speed can also cause coking.If you start the engine very much, the carbon deposits cover the parts so much and the volume of the combustion chamber decreases so much that the car starts to vibrate and the power drops. The increased frictional force simply destroys the cylindrical piston group.
VIDEO
When carbon deposits get under the valve, the adhesion to the seat is broken. In most cases, the valve simply burns out. With poor valve closure, compression drops sharply, as a result, engine power decreases. After a major overhaul, the engine regains all its original characteristics. To carry out such work, the engine is taken out of the car, completely disassembled and troubleshooting is carried out.
Every detail is carefully examined. Measurements are taken and parts to be replaced are identified. After that, it becomes possible to determine the cost of the repair. If the part can be repaired, it is repaired. Parts that cannot be repaired are replaced with new ones. Typically, a major overhaul is done after running 150,000 km. The following works are being carried out:
rings change;
new pistons are installed;
block boring is done;
the crankshaft is ground;
a visual inspection of the starter is performed;
the operation of the generator is checked;
distributor is tested;
a new thermostat is installed;
the pump is being replaced;
new hoses are installed;
a new drive belt is installed;
the radiator is cleaned of dirt and washed.
It is very important to replace all rubber and cork parts during work. The assembly takes place in the same order, but in reverse order. When replacing the cylinder block, the bearing housings also change. They cannot be changed separately.
VIDEO
The carburetor is disconnected from the intake pipe.
Remove all gaskets.
The carburetor heat-insulating shield is removed.
The block head is dismantled.
All pipes taking in warm air are removed.
The exhaust manifold is removed.
The inlet pipe is removed.
The gaskets are removed. The gaskets must be treated very carefully. If they are not damaged, they can be reused.
Candles are unscrewed.
The temperature sensor is removed.
The camshaft is removed.
At the same time, the tensioning roller and the thrust washer behind it are released.
The valves are disassembled.
The valve stops are dismantled.
Each piece is thoroughly washed and dried.
A visual inspection of each element is carried out. Parts that cannot be repaired are replaced with new ones.
The assembly is assembled in reverse order.
1 - tie rod tip; 2 - ball joint of the tie rod end; 3 - pivot arm; 4 - lock nut; 5 - steering rod; 6, 8 - inner tips of steering rods; 7 - bolts of fastening of steering rods to the rack; 9 - bracket for fastening the steering mechanism; 10 - support of the steering mechanism; 11 - protective cover; 12 - connecting plate; 13 - lock plate; 14 - silent block; 15 - damping ring; 16 - support sleeve of the rail; 17 - rail; 18 - steering gear housing; 19 - coupling clamping bolt; 20 - bottom flange of the elastic coupling; 21 - the upper part of the facing casing; 22 - damper; 23 - steering wheel; 24 - ball bearing; 25 - steering shaft; 26 - the lower part of the facing casing; 27 - steering shaft mounting bracket; 28 - protective cap; 29 - roller bearing; 30 - drive gear; 31 - ball bearing; 32 - retaining ring; 33 - protective washer; 34 - sealing ring; 35 - bearing nut; 36 - anther; 37 - stop O-ring; 38 - retaining ring of the stop nut; 39 - rail stop; 40 - spring; 41 - stop nut; 42 - ball joint pin; 43 - protective cap; 44 - ball pin insert; A - a mark on the boot; B - mark on the steering gear housing; C - the surface of the ball joint; D - pivot arm surface
Of course, a car's engine is its most important unit, its "heart". However, in a car, the work of any unit cannot occur completely separately and independently of other units.Everything is interconnected. Therefore, the undercarriage also requires timely repair. Good suspension condition also affects engine performance.
If the front suspension starts to work poorly, there is a violation of the relationship between the chassis and the body of the VAZ 2109 car. Such a malfunction requires immediate repair of the suspension. Further operation of the vehicle is prohibited. It is very dangerous to drive a car that has damage to the steering rack.
Diagnostics of such a malfunction should be carried out only at a service station using a special stand. To carry out diagnostic work, a complete disassembly of the unit is performed. Each part is visually inspected, and the existing runout of the parts is checked.
All oil seals and old gaskets will certainly change. They are disposable and cannot be reused. After assembling and installing parts in place, the car must go through a camber and toe adjustment.
VIDEO
It is necessary to remove the cylinder head (cylinder head) when replacing the gasket, block, as well as when repairing the mechanism of the piston group and its valves or when repairing the head itself. In addition, when tuning the engine or completely disassembling it, you also need to dismantle the cylinder head.
Before starting work, it is necessary that the car is installed on an overpass or on a viewing pit.
Disconnect the negative terminal from the battery.
Drain coolant into a plastic container.
Disconnect the intake pipe from the exhaust manifold.
Dismantle the receiver with the throttle assembly (VAZ-2111). You also need to dismantle the carburetor (VAZ 21083), intake and exhaust manifolds (but you can do without this).
If work is performed on a VAZ 2111, you need to disconnect the "massive" wires attached to the left end of the head. Remove the fuel rail with fuel pipes and injectors.
Disconnect the spark plug high voltage wires. Then we disconnect the coolant sensor connectors and remove the oil pressure level.
On the VAZ-21083, the housing of the auxiliary units must be removed.
Next, the housing of auxiliary units, the distributor sensor, and the fuel pump are dismantled.
Remove the timing belt first. Then removed: the tension roller and the spacer washer. Next, you need to remove the camshaft toothed pulley.
Unscrew the rear nut securing the timing cover to the cylinder head.
Remove the lid cylinder head .
Use a Phillips screwdriver to loosen the clamps, then disconnect the hoses from the cylinder head outlet pipe one by one.
When disassembling the valve train, place a block of wood under the valve disc.
The cylinder head should be assembled and installed in the reverse order.
Recommendations :
Valve stems with engine oil. The same applies to the guide bushings.
Before installing, remove dirt, oil, remnants of the old gasket from the surface of the cylinder block.
Replace cylinder head gasket follows two special centering sleeves.Install the fastening screws, the diagram below shows 4 steps how to tighten them.
First tightening torque of screws - 20 N.m (2 kgf.m);Second - with a moment of 69.4–85.7 N.m (7.1–8.7 kgf.m);The third - with extension at 90 °;Fourth - turn the screws 90 °.
The knock sensor, as the name implies, is necessary to monitor the knock inside the engine, knocks that indicate the presence.
It is quite difficult to determine the reason for the inoperative rear wiper of the VAZ 2109. Below is a list of possible options. 1. They were out of order.
A failed gearbox oil seal causes oil to leak from the gearbox. Replacing the gland box VAZ 2108-2109 is possible.
The ignition switch is important in the operation of the car, since a malfunction of this unit will lead to a stop of work. The initial task of the ignition switch.
Cylinder head (cylinder head) usually removed to replace the gasket or block, or repair the valve mechanism of the piston group or the head itself.The need to remove the cylinder head may also arise in the case of engine tuning or complete disassembly of the engine.
This work is carried out on a viewing pit or overpass.
Disconnect the negative terminal from the battery.
Drain the coolant into a plastic container.
Disconnect the front pipe from the exhaust manifold.
Now dismantle the receiver together with the throttle assembly (VAZ-2111), or the carburetor in the case of (VAZ-21083), as well as the intake and exhaust manifolds (remove the cylinder head without removing the manifolds).
On the VAZ-2111, it is necessary to disconnect the "mass" wires (they are attached to the left end of the head), remove the fuel rail with fuel pipes and injectors.
Disconnect the spark plug high voltage wires and the coolant temperature and oil pressure sensor connectors.
On the VAZ-21083, you will additionally have to remove the housing of the auxiliary units, the ignition distributor sensor and the fuel pump.
Now remove the timing belt, then the idler pulley, spacer washer and the camshaft toothed pulley.
Unscrew the rear nut that secures the timing cover to the cylinder head.
Remove the cover Cylinder head .
Using a Phillips screwdriver, loosen the clamps and disconnect all hoses from the cylinder head outlet in turn.
12. Unscrew the 10 bolts securing the cylinder head using the "10" Allen key.
13. Remove the screws with washers.
14. Now you can remove the cylinder head together with the gasket.
15. When disassembling the valve mechanism, place a block of wood under the valve disc that you are going to dry out.
17. Take it out of the cylinder head guide bush.
18. Take the key on "13" and unscrew the two fastening nuts on the outlet pipe.
19. Remove the gasket and tube.
Assembly and installation of the cylinder head is carried out in the reverse order.
Valve stems and bushing guides are lubricated with engine oil.
Before starting the installation, it is necessary to thoroughly clean the surface of the cylinder block from dirt and oil, as well as the remnants of the old gasket.
Replacing the cylinder head gasket carried out on two special centering sleeves.Now you can install the fixing screws and tighten them in four steps according to the diagram below.
The first tightening of the screws is done with a torque of 20 N.m (2 kgf.m);
The second - with a moment of 69.4–85.7 N.m (7.1–8.7 kgf.m);
The fourth is to turn the screws 90 °.
Now you know how to remove the cylinder head on a VAZ 2109 , on this do-it-yourself replacement of the cylinder head gasket can be considered complete.
Most owners of 8-valve VAZ want to change the cylinder head to a 16-valve one. It's real now. Watch the video on replacing the old cylinder head with a new one with 16v.
VIDEO VIDEO VIDEO VIDEO
It's no secret for anybody that all the records of the VAZ engine power were achieved on engines with 16 valve heads of the cylinder block. And it doesn't matter whether it is an atmospheric or turbocharged engine - there are much more advantages from installing a 16-valve head than disadvantages. Engines with this head of the block can get a much higher filling of the cylinders with the air-fuel mixture, which, of course, leads to an increase in power. Let's take and compare two VAZ engines with the same volume, but with different block heads. A VAZ engine with a volume of 1500 cubic centimeters equipped with an 8-valve cylinder head produces 77 horsepower, and a VAZ engine with the same volume, but equipped with a 16-valve cylinder head, produces about 90 hp.
Video (click to play).
The advantages of a 16 valve engine do not end there. Due to the changed shape of the combustion chamber, the 16-valve engine has a higher knock resistance, this parameter is very important in our time, because the fuel we use every day is poor. Another important advantage is the organization of engine cooling. For 16 valve engines, the cooling system works much better, and this is the reliability of the engine itself. In addition to these important differences, there is also a layout difference. In a 16-valve engine, in contrast to an 8-valve engine, the intake and exhaust tracts are spaced apart on different sides of the head.This facilitates the installation of geometrically correct intake and exhaust manifolds.
