Note. A new drive belt side oil seal and a new valve cover gasket may be used when installing. The camshaft bearing caps will require sealant, and the bearing cap bolts will require tack compound.
Removing
1. Remove the camshaft gear as described in Section Removal from the installation of gear wheels of the drive belt and tension mechanism.
2. Remove the gear drive belt tensioner as described in Section Removal from the installation of gear wheels of the drive belt and tension mechanism (refer to accompanying illustration).
3. Remove the two bolts securing the inner timing belt cover to the cylinder block (refer to accompanying illustration).
4. Turn away the lower bolts fastening an internal top cover of a gear belt to the block of cylinders.
5. Remove the timing belt idler pulley bolt that also goes through the inner cover.
6. Separate the inner cover and, if possible, remove it.
7. Remove the vacuum pump as described in Chapter Brake system.
8. To improve access, release the hoses that run along the top of the valve cover from the mounts and move them to the side. If fuel lines become disconnected, plug open ends to prevent dirt from entering.
9. Turn away nuts or bolts and remove a valvate cover. Remove the gasket.
10. Using a micrometer, measure the axial clearance of the camshaft and compare it with the value given in Specifications (refer to accompanying illustration).
11. If an old camshaft is installed, at this stage it is recommended to measure the valve clearances, as described in Section Checking and adjusting valve clearances.
12. Check the presence of marks on the camshaft bearing caps so as not to confuse them during installation, if necessary, mark them so that they can be installed in their original places. Number the covers.
13. Gradually loosen the bearing cap bolts and struts while evenly depressurizing the valve springs. Remove bolts and racks (memorizing their location) and then the bearing caps. Note that #1 bearing cap is secured with two struts and two extra bolts.
14. Raise the camshaft together with the oil seal (refer to accompanying illustration). Store them in boxes with compartments, or on a clean piece of cardboard divided into eight pieces. Write down the thickness of the shims - this data will be needed later when adjusting the valve clearances. The thickness of the washer is indicated on the underside, but it is better to measure it with a micrometer, as wear may cause the thickness of the washer to be less than indicated on it.
Inspection
1. Inspect the running surfaces of the camshaft bearings and the running surfaces of the cams for gouges, corrosion, or scratches. Replace the camshaft if this damage is found.
2. After each removal, replace the camshaft seal on the drive belt side. Before installing a new oil seal, lubricate its sealing lips.
3. Inspect the running surfaces of the camshaft bearings in the cylinder head and bearing caps. If there are deep scratches or other damage, the cylinder head must be replaced.
4. Examine pushers and adjusting washers on presence of scratches, corrosion and developed places. Replace as needed.
Installation
1. Install all pistons in the middle of the cylinders as described for gear removal in Section Removal from the installation of gear wheels of the drive belt and tension mechanism.
2. Lubricate the pushers and install them in their places. Install washers labeled side down.
3. Lubricate the camshaft bearings. Place the camshaft together with the oil seal on the cylinder head. The oil seal must be positioned so that it is flush with the surface of the cylinder head.
4. Apply sealant (CAF 4/60 THIXO, Rhodorseal 5661 or other suitable) on the matching surfaces of the cylinder head at the installation sites of the right and left camshaft bearing caps (#1 and #5).
5. Replace the covers, making sure that the right seal is properly seated in the bearing cover.
6. Apply a few drops of tack compound to the threads of the bearing cap bolts and posts. Install the bolts and standoffs, and progressively tighten them to the Specifications effort.
7. If a new camshaft is installed, measure the axial clearance and make sure it matches the data given in Specifications.
8. Install the vacuum pump as described in Chapter Brake system.
9. Install the inner upper toothed belt cover, then install and tighten the bolts securing it to the cylinder block and head.
10. Install and tighten the bolt securing the timing belt idler pulley assembly.
11. Install the toothed drive belt tensioner, making sure that the projection on the cylinder block fits into the hole in the tensioner bracket.
12. Install the camshaft gear as described in Section Removal from the installation of gear wheels of the drive belt and tension mechanism.
13. Check valve clearances as described in Section Checking and adjusting valve clearances, and if necessary, adjust them by selecting washers of the desired thickness.
14. Install the valve cover, using a new gasket if necessary, and tighten the mounting nuts or bolts to Specifications effort.
15. Install/connect hoses that have been moved to improve access. If the fuel lines have been disconnected, connect them, and then bleed the fuel system as described in Chapter Power and exhaust systems.
16. Connect the mass cable to the battery.