Pic. 2.41. 1.6L engine camshafts
The camshafts of the 1.6 liter engine are shown in fig. 2.41.
Withdrawal
Disconnect the hose and vent hose of the positive crankcase breather valve.
Pic. 2.42. Removing the coolant pump pulleys and crankshaft
Remove the coolant pump pulley and crankshaft pulley (pic. 2.42).
Remove the timing belt cover.
Loosen the timing belt tensioner pulley bolts, loosen the belt tension, and temporarily secure the tensioner pulley.
Remove the timing belt from the camshaft sprocket.
Loosen the center cover bolts and then remove the cover.
Remove the ignition coil assembly.
Pic. 2.43. cylinder head cover
Loosen the cylinder head cover bolts and then remove the cover (pic. 2.43).
Remove the camshaft sprocket.
Pic. 2.44. Removing the camshaft bearing caps
Remove the camshaft bearing caps and timing chain (pic. 2.44).
Remove camshafts.
Remove hydraulic lifters.
Examination
Check the camshaft journals for wear. If the shaft journals are significantly worn, replace the camshaft.
Pic. 2.45. Checking the protruding part of the camshaft cams
Check the protruding part of the camshaft lobes for damage. If the shaft cams are damaged or their wear exceeds the allowable value, replace the camshaft (pic. 2.45).
Camshaft lobe height
Rated value:
- intake: 43.4484 mm;
- outlet: 43.8489 mm.
Maximum allowable value:
- intake: 42.9484 mm;
- outlet: 43.3489 mm.
Check the surface of the back of the camshaft cams for damage or significant wear and replace the shaft if necessary.
Check up a condition of a bed of a camshaft on absence of damage. If the wear of the camshaft bed exceeds the allowable value, replace the cylinder head assembly or the camshaft bearing caps.
- Axial clearance of the camshaft: 0.10–0.15 mm
Checking the camshaft oil seal
Check the seal lip for wear. If the working edge is worn out, replace an epiploon.
Check up a condition of a surface of a camshaft contacting with a working edge of an epiploon. If the shaft surface is worn, replace the camshaft.
Checking hydraulic lifters
Pic. 2.46. Hydraulic compensator test scheme
fix the surface «A» hydraulic compensator filled with engine oil, and press the stop «B» hydraulic compensator by hand. If emphasis «B» moves, replace the hydraulic lifter (pic. 2.46).
Other characteristic malfunctions of the hydraulic compensator are given in table 2.6.
Timing Chain Check
Check circuit elements (bushings and plates) for no wear. Replace chain if wear is excessive.
Pic. 2.47. Timing chain
Installation
Install the hydraulic lifters in place.
Pic. 2.48. Alignment of the timing chain with the chain sprockets of the intake and exhaust camshafts
Align the timing chain with the chain sprockets of the intake and exhaust camshafts, as shown in Figure 2.48.
Pic. 2.49. Installation of camshafts
Lubricate the camshaft bearing journals with engine oil, then install the camshaft in place (pic. 2.49).
Pic. 2.50. Identification marks on bearing caps
Install the camshaft bearing caps. The identification marks on the bearing caps are used to identify the location of the cap installation (intake/exhaust valve side) (pic. 2.50).
- I: intake camshaft.
- E: exhaust camshaft.
Pic. 2.51. The order of tightening the bolts of the camshaft bearing caps
Tighten the camshaft bearing cap bolts with a nominal tightening torque in two or three steps in the order indicated by the numbers in Figure 2.51.
The moment of an inhaling of bolts of fastening of a cover of the bearing of a camshaft: 12–14 Н·м.
Pic. 2.52. Pressing the camshaft oil seal with a special tool
With a special tool (mandrel for installing the camshaft oil seal 09221-21000) press in the camshaft seal (pic. 2.52).
Make sure the lip of the camshaft oil seal is lubricated with engine oil. Slide the oil seal onto the camshaft from the timing belt sprocket side, then tap the mandrel with a hammer to install the oil seal so that it is flush with the surface.
Pic. 2.53. Camshaft sprocket installation
Set the sprocket (for belt) camshaft and tighten the bolt of its fastening with the nominal tightening torque (pic. 2.53).
Tightening torque of the camshaft sprocket bolt (for belt): 80–100 Nm.
Align the marks on the crankshaft and camshaft sprockets with the corresponding alignment marks and set the No. 1 cylinder piston to TDC on the compression stroke.
Install the cylinder head cover.
The moment of an inhaling of bolts of fastening of a cover of a head of cylinders: 8–10 Н·м.
Pic. 2.54. Installing the center cover
Install ignition coil assemblies, high voltage spark plug wires and center cap (pic. 2.54).
Install the timing belt, and then, when the tensioner pulley tightens the belt, tighten the tensioner fastener.
Install the timing belt covers.
Tightening torque of the timing belt cover bolts: 8–10 Nm.
Install the water pump pulley and crankshaft pulley.