Withdrawal
1. Disconnect the crankcase breather hose and positive crankcase breather hose.
2. Remove the water pump pulley and crankshaft.
3. Remove a casing of a gear belt.
4. Move the toothed belt tensioner towards the water pump and temporarily secure it in this position.
5. Remove the toothed belt from the camshaft pulley.
6. Remove the camshaft pulley.
7. Remove the ignition coil (only on 1.1L engine).
8. Remove the cylinder head cover.
9. Remove the rocker shaft assembly.
10. Remove the camshaft by moving it towards the front of the engine (engine 1.1 l).
11. Remove the camshaft.
Examination
Camshaft
1. Check the camshaft for uneven wear, cracks or damage.
2. At two points, measure the height of each camshaft lobe.
Height of camshaft cams, mm:
nominal:
- intake valve cams:
- 1.3L engine: 42.8575
- 1.1L engine: 34.8729
- exhaust valve cams:
- 1.3L engine: 42.7354
- 1.1L engine: 35.1258
minimum allowable:
- intake valve cams:
- 1.3L engine: 42.3575
- 1.1L engine: 34.8729
- exhaust valve cams:
- 1.3L engine: 42.2353
- 1.1L engine: 35.0258
3. Check the cam surfaces for uneven wear and damage.
4. Check each camshaft bearing for damage. If the bearing surface is excessively damaged, replace the cylinder head or camshaft bearing cap.
Camshaft front O-ring
1. Check the sealing ring lips for wear. If the lip is worn or damaged, replace the O-ring.
2. Check the surface of the camshaft in contact with the O-ring. If this surface is evenly worn, replace the camshaft.
Camshaft end play, mm:
- 1.3L engine: 0.07–0.28
- 1.1L engine: 0.07–0.19
Installation
1. Before installing, apply a thin layer of clean engine oil to all sliding surfaces of the camshaft. Install the camshaft.
2. Install the camshaft bearing caps (engine 1.3 l). Install the ignition coil (engine 1.1 l).
3. Install the rocker shaft and rocker arms.
4. Lubricate with engine oil the working edges and the outer surface of the sealing ring and with a special tool 09221–21000 install the sealing ring on the front of the camshaft.
Using a hammer on the special tool 09221-21000, install the O-ring until it stops in the seat.
5. Install the camshaft pulley and secure it with a bolt.
Tightening torque: 80–100 Nm.
6. Align the timing mark of the camshaft and the timing mark of the crankshaft pulley with the pointers, while the piston of the 1st cylinder will be at TDC on the compression stroke.
7. Install the gasket in the recess of the cylinder head cover.
8. Temporarily install the cylinder head cover.
9. Start the engine and let it run at idle speed.
10. Tighten the cover bolts to the required torque.
Tightening torque: 8–10 Nm.
11. Establish casings of a gear belt.
12. Install the water pump pulley and crankshaft pulley.