If a leak of engine oil or coolant is detected at the junction of the cylinder head with the cylinder block, remove the cylinder head and replace the head gasket. A leak can also occur due to warping of the block head due to overheating.
WARNING The head gasket is a one-time use, so every time the head is removed, the head gasket must be replaced.
1. Disconnect the wire from the “-” terminal battery.
2. Disconnect the wire from the coolant temperature sensor.
3. Disconnect the wire from the oil pressure sensor. 4. Set the piston of the 1st cylinder to the TDC position of the compression stroke (see “Installing the piston of the 1st cylinder to the TDC position of the compression stroke”). 5. Drain the coolant (see “Replacing the coolant”). 6. Remove the thermostat (see “Removing and installing the thermostat”). 7. Disconnect exhaust pipe muffler from the exhaust manifold (see “Replacing the exhaust pipe of the muffler”). 8. Remove the air filter (see “Removal and installation air filter"). 9. Remove the front cover of the camshaft drive belt (see “Replacing the camshaft drive belt on VAZ 2108, VAZ 2109, VAZ 21099 cars and adjusting the belt tension”). 10. Remove the cylinder head cover (see “Adjusting the clearances in the valve drive”).
11. Secure the camshaft gear from turning by inserting a screwdriver into its hole and resting it against the pin; loosen the camshaft gear mounting bolt (for clarity, the operation is shown on a VAZ 2108, VAZ 2109, VAZ 21099 engine removed from a vehicle).
12. Remove the drive belt from the camshaft gear, tension roller, water pump toothed pulley, move the belt to the side (see “Replacing the camshaft drive belt on VAZ 2108, VAZ 2109, VAZ 21099 cars and adjusting the belt tension”).
13. Unscrew the camshaft gear mounting bolt and remove it together with the washer (for clarity, the operation is shown with the engine removed).
14. Using two screwdrivers, remove the gear from the camshaft. At the same time, do not damage the camshaft oil seal (for clarity, the operation is shown on a VAZ 2108, VAZ 2109, VAZ 21099 engine removed from a car).
15. Loosen the clamp and disconnect the fuel supply hose to fuel pump. 16. Disconnect hoses and wires from the carburetor, drive rod air damper and throttle drive cable (see “Removing and installing the carburetor”).
17. Disconnect the central high-voltage wire from the ignition distributor cover.
18. Use a screwdriver to press out the spring clip and disconnect the block with low-voltage wires from the ignition distributor terminal. 19. Disconnect the tube from the vacuum corrector of the ignition distributor. 20. Disconnect the hose vacuum booster from the engine intake pipe. 21. Loosen the clamp and disconnect the radiator supply hose from the water cooling jacket pipe (see “Removing and installing the cooling system radiator”).
22. Loosen the clamp and disconnect the heater supply hose.
23. Loosen the clamp and disconnect the heater outlet hose.
24. Loosen the ten cylinder head bolts in the order shown, then finally unscrew the cylinder head bolts and remove the bolts and washers.
25. Lift the cylinder head slightly, slide the cylinder head so that the end of the camshaft comes out of the hole in the rear drive belt cover, and remove the cylinder head.
WARNING Do not jam a screwdriver or other tools between the cylinder head and the cylinder block.
HELPFUL ADVICE To remove the head from the block, insert a screwdriver under an exhaust manifold. Using it as a lever, lift the block head.
26. Remove the head gasket.
27. The cylinder head bolts become stretched with repeated use. Replace with new cylinder head bolts whose length exceeds 135.5 mm. Before installing the cylinder head, lubricate the bolts with a thin layer of engine oil. 28. Clean the mating surfaces of the cylinder head and cylinder block (the surfaces must be dry and clean) and remove oil from the threaded holes in the block for the cylinder head mounting bolts.
29. Install a new head gasket on the cylinder block (the gasket must be dry and clean) along the installation sleeves. In this case, the hole for the passage of oil in the head gasket (with a copper edging) should be located between the 3rd and 4th cylinders.
30. Install the cylinder head on the cylinder block, first making sure that the crank and camshaft s are in the TDC position (both valves of the 1st cylinder must be closed). Tighten the cylinder head bolts in the specified sequence in four stages: 1 - to a torque of 20 Nm (2 kgf-m); 2 - torque 69.4-85.7 Nm (7.1-8.7 kgf-m); 3 - tighten the bolts 90°; 4 - finally tighten the bolts 90°.
31. Install the parts on the cylinder head and connect the hoses and wires to the cylinder head in the reverse order; do not turn the crankshaft and camshaft before installing the camshaft drive belt. Install the camshaft gear with the protruding part of the hub facing the engine. Check and, if necessary, adjust the valve clearances (see “Adjusting the clearances in the valve drive”). Adjust the tension of the camshaft drive belt (see “Replacing the camshaft drive belt on VAZ 2108, VAZ 2109, VAZ 21099 cars and adjusting the belt tension”).
The main sign indicating a faulty cylinder head gasket on a VAZ 2109 is the appearance of an oil or coolant leak at the junction of the cylinder head and the engine block. In addition to a malfunction of the gasket itself, the leak could also have caused warping of the head as a result of engine overheating, but in any case, disassembly is necessary.
To perform dismantling, we prepare a standard set of tools. The work order is as follows:
- Disconnect the power wires from the coolant temperature control sensors and from the emergency oil pressure sensor in the system.
- Next, remove the thermostat, after draining the cooling system.
- Remove the air filter housing. There is no need to remove the carburetor itself since it will not interfere.
- Disconnect the exhaust muffler pipe from the exhaust manifold.
- Now we need to remove the drive gear camshaft, but first set the piston of the first cylinder to position top dead points. Then we remove protective case camshaft drive belt and loosen the bolt securing the gear, having previously secured it from turning.
- Now we remove the camshaft drive belt, after which, after finally unscrewing the fastening bolt, we remove the gear.
- We press the latch and disconnect the block with the supply wires from the ignition distributor. Also disconnect the central high-voltage wire.
- Loosen the clamps and remove the fuel supply hose from the fuel pump.
- Disconnect the air drive rods from the carburetor and throttle valves. From solenoid valve disconnect the power cable.
- Remove the vacuum booster hose from the intake pipe, disconnect the tube from the vacuum ignition corrector.
- Loosen the clamps and remove the car interior heating hoses from the pipes.
- Now you can remove the block head. Using a socket with an extension, unscrew the bolts securing it. Jerk it a little to move it out of place and carefully remove it.
- Remove the sealing gasket.
On this renovation work The removal and replacement of the cylinder head gasket for the VAZ 2109 has been completed. Before installing the head, check the length of the head mounting bolts. The length should be 135.5mm, if they are stretched, replace them. Full assembly do in reverse order.
This work is carried out on an inspection pit or overpass.
- Disconnect the negative terminal from the battery.
- Drain the coolant into a plastic container.
- Disconnect the exhaust pipe from the exhaust manifold.
- Now remove the receiver along with throttle assembly(VAZ-2111), or carburetor in the case of (VAZ-21083), as well as intake and exhaust manifolds (remove the cylinder head and without removing the manifolds).
- On a VAZ-2111, you need to disconnect the “mass” wires (they are attached to the left end of the head), remove the fuel rail with fuel pipes and injectors.
- Disable high voltage wires from spark plugs, as well as connectors for coolant temperature and oil pressure level sensors.
- On the VAZ-21083 you will additionally have to remove the body auxiliary units, ignition distributor and fuel pump.
- Now remove the timing belt, after that tension roller, spacer washer and toothed pulley camshaft
- Unscrew the rear fastening 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 the hoses from the cylinder head exhaust pipe one by one.
12. Unscrew the 10 cylinder head mounting bolts using a “10” hexagon.
13. Remove the screws and washers.
14. Now you can remove the cylinder head along with the gasket.
15. When disassembling the valve mechanism, place a wooden block under the valve plate that you are going to dry out.
16. Dry the valve.
17. Remove it from the cylinder head guide sleeve.
18. Take the key at “13” and unscrew the two fastening nuts on the outlet pipe.
19. Remove the gasket and pipe.
- Valve stems and bushing guides are lubricated motor oil.
- Before starting installation, it is necessary to thoroughly clean the surface of the cylinder block from dirt and oil, as well as remnants of the old gasket.
- Replacing the cylinder head gasket carried out using two special centering bushings.
- Now you can install the mounting screws and tighten them in four steps according to the diagram below.
The first tightening of the screws is carried out with a torque of 20 N.m (2 kgf.m);
Third - extension by 90°;
Now you know how to remove the cylinder head on a VAZ 2109, at this point replacing the cylinder head gasket with your own hands can be considered complete.
According to many years of experience of various car enthusiasts, replacing the cylinder head of a VAZ 2109 is most often associated with problems arising from the gasket. But there may be others that can cause the engine to overheat or even seize.
Tuning
Qualified adjustment, modification 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. Typically, when tuning, the channels are bored and smoothed, thereby reducing the turbulence that reduces power. The valves are changed to larger ones and ground to seats. Tuning may also involve replacing standard valve guides with bronze ones.
Valve lapping
Lapping control is carried out as follows:
- the assembled head 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, this means that the work was done efficiently and the valves were ground in correctly. After all faults have been eliminated, you can begin installing the head.
Installation
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 force. It would be useful to read additional material on this topic and watch video instructions.
As you can see, there are certain difficulties in modifying 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.
It is necessary to remove the cylinder head (cylinder head) when replacing the gasket, block, and also when repairing the mechanism. 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 vehicle is installed on an overpass or on inspection hole.
Removing the cylinder head on a VAZ 2109
- Disconnect the negative terminal from the battery.
- Drain the coolant into a plastic container.
- The exhaust pipe should be disconnected from the exhaust manifold.
- Remove 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 the work is performed on a VAZ 2111, you need to disconnect the “mass” wires attached to the left end of the head. Remove the fuel rail with fuel pipes and injectors.
- Disconnect the high voltage spark plug 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 the auxiliary units, the distributor sensor, and the fuel pump are dismantled.
- First remove the timing belt. Then the tension roller and spacer washer are removed. Next, you need to remove the camshaft timing pulley.
- Unscrew the rear mounting nut securing the timing cover to the cylinder head.
- Remove cover cylinder heads.
- Use a Phillips screwdriver to loosen the clamps, then you need to disconnect the hoses from the cylinder head exhaust pipe one by one.
How to remove the cylinder head on a VAZ 2109. Replacing the cylinder head gasket with your own hands
- Unscrew the 10 bolts that secure the cylinder head using a 10mm hexagon.
How to remove the cylinder head on a VAZ 2109. Replacing the cylinder head gasket with your own hands
- Remove the screws and washers.
How to remove the cylinder head on a VAZ 2109. Replacing the cylinder head gasket with your own hands
- Remove the cylinder head with gasket.
How to remove the cylinder head on a VAZ 2109. Replacing the cylinder head gasket with your own hands
Also check out
- When parsing valve mechanism a wooden block must be placed under the valve plate.
How to remove the cylinder head on a VAZ 2109. Replacing the cylinder head gasket with your own hands
- Dry the valve. Remove it from the cylinder head guide bushing.
How to remove the cylinder head on a VAZ 2109. Replacing the cylinder head gasket with your own hands
How to remove the cylinder head on a VAZ 2109. Replacing the cylinder head gasket with your own hands
- Using a key “13”, unscrew the 2 nuts securing the inlet pipe.
How to remove the cylinder head on a VAZ 2109. Replacing the cylinder head gasket with your own hands
- Remove the gasket and pipe.
Assemble and install the cylinder head in the reverse order.
- Valve stems with engine oil. The same applies to guide bushings.
- Before installation, remove dirt, oil, and remnants of the old gasket from the surface of the cylinder block.
- Replace cylinder head gasket follows two special centering bushings.
- Install the mounting screws; the diagram below shows 4 steps on how to tighten them.
How to remove the cylinder head on a VAZ 2109. Replacing the cylinder head gasket with your own hands
- First screw tightening torque- 20 N.m (2 kgf.m);
- Second- with a moment of 69.4-85.7 N.m (7.1-8.7 kgf.m);
- Third- with an extension of 90°;
- Fourth- turn the screws by 90°.
WARNING
The cylinder head is replaced with the bearing housings assemblies, since they are processed together.
1. Remove the cylinder head from the VAZ 2108, VAZ 2109, VAZ 21099 (see “Replacing the cylinder head gasket”).
2. Unscrew the fastening screw and disconnect the heating fitting from the carburetor. If you cannot unscrew the screw, loosen the clamp and remove the hose from the fitting.
3. Unscrew the four carburetor mounting nuts (two of them are located on the opposite side).
4. Remove the carburetor from the intake pipe.
5. Carefully remove the carburetor gaskets.
6. Unscrew the two nuts securing the carburetor heat insulation shield.
7. Loosen the nut on the fitting.
8. Remove the carburetor heat shield.
9. Unscrew the two nuts securing the warm air intake pipe.
10. Unscrew the nut securing the eye.
11. Remove the ring and the warm air intake pipe.
12. Unscrew the nine nuts securing the intake pipe and exhaust manifold.
13. Remove the exhaust manifold.
14. Remove the inlet pipe.
HELPFUL ADVICE
After removing the exhaust manifold and intake pipe, place wood shims under the cylinder head to prevent damage to the valves protruding from the cylinder head.
15. Remove the two gaskets.
NOTE
Remove the sealing gaskets carefully. If the exhaust manifold and intake pipe gaskets are not damaged or too compressed, they can be reused. Carefully remove the burnt exhaust manifold and intake pipe gaskets using a screwdriver.
16. Remove the spark plugs from the cylinder head.
17. Unscrew the coolant temperature sensor (DTOZH).
18. Unscrew the sensor warning lamp emergency oil pressure.
19. Remove ten nuts securing both camshaft bearing housings.
20. Remove both camshaft bearing housings from the cylinder head.
21. Remove the camshaft.
22. Remove the oil seal from the front end of the camshaft.
23. Unscrew the nut securing the tension roller.
24. Remove the tension roller and thrust washer located under the tension roller.
25. Remove the valve pushers along with the adjusting washers.
WARNING
After removing the next valve tappet, mark it and the adjusting washer serial number to place them in place during assembly.
NOTE
The valve drive consists of the following parts: 1, 2 - valves; 3 - outer spring; 4 - internal spring; 5 - upper plate; b - cracker; 7 - lower plate.
All these parts must be removed from the cylinder head.
26. Mark the valves with the cylinder number to ensure that the valves are in place during assembly. Marking can be applied using a core as close as possible to the center of the valve: the valves of the first cylinder - one point, the second - two, etc.
27. Place a suitable stop under the valve to be removed.
28. Install a valve spring compressor on the cylinder head. Use it to compress the valve springs and remove the crackers. Gradually loosening the pressure on the handle of the device, completely release the valve spring and remove the device from the head.
29. Remove the outer valve spring and retainer.
30. Remove the inner valve spring.
31. Remove the valve from the cylinder head.
32. Carefully remove the oil seal without damaging the valve guide.
33. Remove the valve spring support washer (plate). Remove the remaining valves in the same way.
34. Wash the cylinder head parts in gasoline, wipe and dry them.
35. Clean the combustion chambers from carbon deposits. Inspect the cylinder head. If there are cracks in the cylinder head or burn marks in the combustion chambers, replace the cylinder head.
36. Check the flatness of the surface adjacent to the cylinder block. To do this, place a metal ruler with its edge on the surface of the cylinder head, centered along, and then diagonally, and use a feeler gauge to measure the gap between the plane of the cylinder head and the ruler. Replace the cylinder head if the gap exceeds 0.1 mm.
37. Clean carbon deposits from the valves. This can be done with a suitable metal tool.
38. Inspect the valves. Replace valves with the following defects: deep marks and scratches on the working chamfer, cracks, deformation of the valve stem, warping of the valve disc, burn marks. Shallow marks and scratches on the working chamfer can be removed by lapping the valves (see “Lapping valves”).
NOTE
Rice. 4.5. Valve plate sizes
Damage to the working chamfer of valves that cannot be removed by grinding can be eliminated by grinding on a special machine. When grinding, you must maintain the dimensions indicated in Fig. 4.5. The different dimensions for the VAZ 21083 engine are given in parentheses.
39. Check the condition of the valve springs. Replace bent, broken or cracked valve springs. Check the elasticity of the valve springs. To do this, measure the height of the springs when free and then under two different loads. If the valve spring does not meet the required specifications, replace the spring.
NOTE
Parameters of valve springs to determine their elasticity:
outer valve spring:
free height......45.2 mm;
height under load (26.0+1.7) kgf.......33.7 mm;
height under load (46.2+2.4) kgf......24.7 mm;
inner spring:
free height.........................34.1 mm;
height under load (9.0+0.8) kgf........29.7 mm;
height under load (27.5+1.5) kgf......20.7 mm.
40. Check the condition of the valve seats. The working chamfers of the valve seats should be free of wear, pitting and corrosion. Minor damage (small marks, scratches, etc.) can be removed by grinding the valves.
NOTE
More significant defects in valve seats can be eliminated by grinding.
Rice. 4.6. Valve seat sizes: a - intake valve seat; b - saddle exhaust valve; I - new saddle; II - saddle after repair
When grinding, maintain the dimensions indicated in Fig. 4.6. First, the chamfer is ground at an angle of 20°, then the chamfer at an angle of 45°. After grinding the seats, the valves must be ground in, then thoroughly cleaned and blown compressed air the block head so that there are no abrasive particles left in the channels and combustion chambers. The different dimensions for the VAZ 21083 engine are given in parentheses.
41. Check the gap between the guide bushings and the valves (Fig. 4.7).
NOTE
Rice. 4.7. Dimensions of valves and their guides
Gap between valve and guide sleeve, mm:
nominal for intake valves................0,022-0,055;
nominal for exhaust valves...............0.029-0.062;
extremely permissible clearance for intake and exhaust valves...0.3.
The clearance is calculated as the difference between the diameter of the hole in the bushing and the diameter of the valve stem. If the gap is less than the maximum permissible, try replacing the valve. If the gap exceeds the maximum permissible, replace the guide sleeve.
42. Press out the defective valve guide from the side of the combustion chamber using a special mandrel.
43. Insert the new valve guide into the special mandrel.
NOTES
Valve guides with retaining rings are supplied as spare parts. The valve guides are increased by 0.2 mm outside diameter and a reduced diameter of the valve hole.
44. Using a mandrel, press in the valve guide from the camshaft side until the retaining ring stops in the cylinder head.
45. Expand the hole in the valve guide using a reamer to 8.022-8.040 mm for intake valves and to 8.029-8.047 mm for exhaust valves. After this, grind the valve seats as described above, centering the tool on the hole in the bushing.
46. Inspect the valve lifters. If the valve lifter face is nicked, scratched or otherwise damaged, replace the valve lifters.
47. Inspect the valve lifter shims. Their working surfaces should not have burrs, nicks, scratches, marks of stepped or uneven wear, rubbing metal. In case of such defects, the washers must be replaced. Concentric marks of running-in with the camshaft cams are allowed on the washers.
48. Measure the length of the cylinder head bolts, as repeated tightening will stretch the cylinder head bolts. If the length of the cylinder head bolts exceeds 135.5 mm, replace the bolts.
49. To check the tightness of the cylinder head, plug the hole in the cooling jacket pipe at the rear end of the cylinder head, turn the cylinder head over with the combustion chambers facing up and pour kerosene into the cooling jacket channels. If kerosene leaks appear, it means that the cylinder head is not sealed and the cylinder head must be replaced.
50. If installing an old valve, remove the burrs from the grooves under the crackers. After this, it is necessary to grind the valve to the seat (see “Lapping valves”).
51. Install the valves into the cylinder head in accordance with the previously made markings, having previously lubricated the valve stems with engine oil.
52. Install the lower valve spring retainers.
53. Install valve stem seals(see “Replacing valve stem seals”).
54. Replace the camshaft if there are signs of wear, scoring and deep marks on the camshaft journals and cams. In workshops equipped special tool and accessories, you can check radial runout camshaft journals (radial runout of the journals should not exceed 0.02 mm) and the gap between the support holes and the camshaft journals, which should not exceed 0.2 mm (the gap for new parts is 0.069-0.11 mm).
55. Install the camshaft and bearing housings (see “Replacing valve stem seals”).
56. Install gaskets, exhaust manifold and intake pipe.
57. Install the head on the cylinder block (see “Replacing the cylinder head gasket”), check the clearances in the valve drive and, if necessary, adjust them (see “Adjusting the clearances in the valve drive”).
The cylinder head is the cylinder head, it must be removed if the gasket “blows through”, when it is necessary to repair the head or the entire engine itself.
Before starting work on removing the cylinder head, the car is placed on an inspection hole or overpass.
Let's start with the robot to remove the cylinder head:
1. Disconnect the terminals from the battery, only the negative one is possible.
2.Drain the coolant from the cylinder block;
3.Remove the “air” from the carburetor;
4.Unscrew and remove the intake and exhaust manifolds;
5. Pull out the high-voltage spark plug wires and disconnect the chips on the temperature sensor and on the oil level sensor;
6. Dismantle the ignition distributor and fuel pump;
7.Remove the timing cover and remove the belt, after removing the belt, unscrew and pull out the tension roller, spacer washer and camshaft pulley;
8.Unscrew the nut that secures the timing cover to the cylinder head.
9.Pull off the cylinder head cover;
10.Using a screwdriver, release and remove all hoses from the cylinder head exhaust pipe.
11.Using a “10” hexagon, unscrew all the bolts that secure the head to the block (10 bolts) and pull them out along with the washers;
12.Slowly remove the head, the gasket should remain on the cylinder head;
We carry out necessary repairs and reassemble in reverse order.
Before installation of cylinder head It is very good to clean off dirt, oil, and possible remnants of the old gasket on the planes of the head and block.
The cylinder head screws are tightened using torque wrench in four stages and only in the order shown in the photo:
Stage I – tightening the bolts with a torque of 20 N/m;
Stage II – tightening the bolts with a torque of 75 N/m;
ІІІ stage - tightening all bolts a quarter turn;
I V stage - repeat Stage III.
Video on removing the cylinder head on a VAZ 21099:
