Removing
1. Disconnect the negative terminal from the battery and remove the cylinder head cover.
1.6 liter engine models
2. Remove the camshaft pulley.
3. Remove the ignition coil.
4. Remove the top bolt securing the thermostat housing to the left front end of the cylinder head.
5. Carefully remove the oil feed pipe to the upper camshaft bearing caps. Pay attention to the O-rings installed in each pipeline connection.
6. The camshaft bearing caps are numbered 1 to 5, with cap #1 on the gearbox side. If the covers are not numbered, number them. Also mark the position of each cover.
7. Loosen the camshaft bearing cap nuts evenly and gradually. Once the valve spring pressure has ceased, unscrew the nuts completely.
8. Remove bearing caps.
9. Remove the camshaft from the cylinder head and the O-ring from the camshaft.
10. Using a rubber suction cup, remove the pushrods and place them in a suitable container so that they can be reinstalled after assembly. If necessary, the shim can be removed from the top of the valve stem and stored with an appropriate tappet.
Engine models 1.8 and 2.0 liters
11. Remove both cylinder head covers.
12. Remove both pulleys from the camshafts together with the hubs, as well as the toothed belt tensioner pulley.
13. Remove the upper inner casing of the toothed belt.
14. Evenly and gradually unscrew the twelve bolts securing the camshaft bearings to the cylinder head. Remove bolts and remove bearing housings.
15. Since both camshafts are identical, it is necessary to mark the intake camshaft and the exhaust camshaft before removing them.
16. Remove the camshafts and remove the o-rings from the camshafts.
17. Using a rubber suction cup, remove the hydraulic tappets and place them in a suitable container so that they can be reinstalled after assembly.
Examination
1. Check the condition of the running surfaces of the camshaft and cam bearings for wear. If there is any wear on the camshaft, it must be replaced. Check up a condition of working surfaces of bearings of a cam-shaft in a head of the block of cylinders. If the bearing surfaces are worn, the cylinder head must be replaced.
2. Check up a condition of pushers. If there is wear on the tappets from the camshaft lobes, the tappet must be replaced (possibly with a camshaft).
Installation
1.6 liter engine models
1. Install shims on top of valve stem. In no case do not change the shims in places, because. this will lead to a violation of the valve clearance.
2. Lubricate the tappets with engine oil and install the cylinder head, and the pushers should be in their original places.
3. Lubricate the camshaft cams with engine oil, then install the camshaft into the cylinder head. Temporarily install the pulley on the camshaft and align the mounting holes in the pulley with the hole in the cylinder head. Check that the dowel pin is blocking the flywheel pulley.
4. Check that the bearing caps are thoroughly clean. Install bearing caps using previously made markings.
5. evenly and gradually (every time for 1 turn) tighten the camshaft bearing caps until they touch the cylinder head. After that, in a spiral, tighten all the nuts to the required torque.
6. Check the connections of the oil supply pipe to the camshaft bearings and the O-rings for wear and replace if necessary. Lubricate the O-rings with engine oil and carefully install the piping.
7. Check the condition of the O-ring and replace if necessary. Install the top mounting bolt to the thermostat housing and tighten to the specified torque.
8. Install the ignition coil.
9. Install a new camshaft seal and camshaft pulley.
10. Check valve clearances.
11. Install the cylinder head cover and connect the negative terminal to the battery.
Engine models 1.8 and 2.0 liters
12. Thoroughly clean the camshaft bearing housings.
13. Lubricate the hydraulic tappets with engine oil and reinstall them. Check that each pusher pivots freely in the hole.
14. Lubricate the bearings and camshaft lobes with engine oil and install the camshafts in the head as follows:
- 1.8 liter engine models: the exhaust camshaft groove must be at the 12 o'clock position, and the intake camshaft groove at the 11 o'clock position;
- 2.0 liter engine models: the exhaust camshaft groove must be at the 3 o'clock position and the intake camshaft groove at the 11 o'clock position.
15. Check that the guide pins are in place, i.e. at each corner of the cylinder head.
16. Lubricate the space for the gasket and the holes for the mounting bolts with silicone grease.
17. Lubricate the camshaft bearings with engine oil and install the bearing housings on the camshafts. Install the mounting bolts.
18. Consistently and gradually, in a certain order, tighten the bearing housing bolts in two stages.
19. Establish the top internal casing of a gear belt.
20. Install the toothed belt tensioner pulley.
21. Install the cylinder head cover.
22. Install new O-rings, hubs and camshaft pulleys.