Engines 1.4, 1.6 and 1.8 l
Removal
1. Remove the oil filler cap, unscrew the mounting bolts and remove the engine protective cover.
2. Disconnect the electrical wiring, unscrew the mounting screws and remove the ignition module (see Chapter Engine electrical equipment).
3. Loosen the mounting clamps and disconnect the crankcase ventilation hoses from the left edge of the timing cover.
4. Gradually and evenly loosen and unscrew the cover fastening screws.
5. Remove the timing cover from the cylinder head. Remove the sealing rings and gasket from the cover, check their condition, and replace them if necessary.
Installation
1. Make sure that the mating surfaces of the cover and head are absolutely clean and dry. Place the seals in the cover, temporarily fixing them with consistent grease.
2. Apply a coat of suitable sealant to the mating surface of the cylinder head in the area of the right camshaft bed covers and in the semi-circular cutouts on the left side of the casting.
3. Carefully place the timing cover in its regular place, checking the correct placement of the seals. Screw in the mounting bolts and, moving in a spiral from the center to the edges, tighten them evenly with the required force.
4. Restore the original connection of the crankcase ventilation hoses, making sure that the fastening clamps are securely tightened.
5. Reinstall the ignition module (see Chapter Engine electrical equipment).
6. Install the engine protective cover.
Engines 1.8 l
Removal
1. Remove the engine cover (see above Engines 1.4, 1.6 and 1.8 l - Removal).
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2. Loosen the mounting clamps and disconnect the crankcase ventilation hoses from the left edge of the timing cover.
3. Disconnect the electrical wiring, unscrew the mounting screws and remove the ignition module (see Chapter Engine electrical equipment).
4. Disconnect the wiring connector from the coolant temperature sensor.
5. Disconnect the coolant hose from the thermostat housing. Unscrew the bolts securing the hose support bracket to the timing cover and intake manifold. Loosen the clamp and move the hose to the side — get ready to collect any spilled coolant.
6. In several steps, evenly loosen and unscrew the cover mounting bolts.
7. Lift up, separate the cover from the cylinder head, remove the sealing gasket. Check the condition of the gasket, if necessary, prepare a replacement.
Installation
1. Make sure that the mating surfaces are absolutely clean and dry, place the new gasket in the dry-wiped receiving groove of the cover.
2. Carefully place the timing cover in its regular place, checking the correct placement of the seals. Screw in the mounting bolts and, moving in a spiral from the center to the edges, tighten them evenly with the required force.
3. Connect the coolant hose to the thermostat housing, secure the hose to the bracket on the roof and the intake manifold. Check the coolant level, and adjust if necessary (see Chapter Routine maintenance).
4. Connect the electrical wiring to the temperature sensor.
5. Restore the original connection of the crankcase ventilation hoses, making sure that the fastening clamps are securely tightened.
6. Reinstall the ignition module (see Chapter Engine electrical equipment).
7. Install the engine protective cover.
2.0L Engines
Removal
1. Remove the air cleaner assembly (see Chapter Power and exhaust systems).
2. Remove the upper section of the timing belt cover (see Removal and installation the timing belt cover).
3. Loosen the fastening clamps and disconnect the crankcase ventilation hoses from the timing cover.
4. Unscrew the mounting bolts and remove the spark plug protective cover. Remove the protective caps from the spark plugs, disconnect and move the high-voltage wires to the side.
5. Disconnect and move aside the electrical wiring from the camshaft position (CMP) sensor.
6. In several steps, evenly loosen and unscrew the timing cover mounting bolts.
7. Separate the cover from the cylinder head, remove the gasket and remove the sealing rings from the holes for the mounting bolts. Carefully inspect the sealing elements and replace them if necessary.
Installation
1. Make sure the mating surfaces are absolutely clean and dry, then place the sealing gasket into the cover's receiving groove. After lightly lubricating with grease, place the sealing rings into the holes for installing the mounting bolts.
2. Apply a coat of suitable sealant to the cylinder head cover mating surface in the area of the right camshaft bed covers and in the semi-circular cutouts on the left side of the casting.
3. Carefully place the timing cover in its regular place, checking the correct placement of the seals. Screw in the mounting bolts and, moving in a spiral from the center to the edges, tighten them evenly with the required force.
4. Restore the original connection of the crankcase ventilation hoses, making sure that the fastening clamps are securely tightened.
5. Carefully place the high voltage wire terminal tips onto the spark plugs.
6. Connect the wiring to the CMP sensor, install the protective cover of the high-voltage wiring, screw in and securely tighten the bolts that secure it.
7. Place the wiring harness in place and tighten the retaining nut securely.
8. Install the upper timing belt cover (see above Engines 1.4, 1.6 and 1.8 l - Installation).
9. Install the air filter housing - see. Power supply system.
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