Removing the cylinder head cover
8 valve engine
The cylinder head cover - often also called the valve cover - is dismantled in our engines as follows:
- Unscrew the cable duct from the valve cover and set aside.
- Use pliers to remove the hose clamp from the engine ventilation hose and remove the hose. Also remove the thin cylinder head cover hose.
- Unscrew fixing bolts of a cover of a head of the block of cylinders.
- Carefully remove the cylinder head cover from the camshaft housing taking care not to damage the gasket.
- Replace damaged gasket.
- When mounting, tighten the fixing bolts starting from the middle of the cover crosswise by 8 Nm.
Removing the cylinder head cover
16V
- Engine 16V with a displacement of 1.6 liters: disconnect the battery ground wire
- Disconnect all wire connectors at the top of the intake manifold.
- Remove the cable duct from the clips and set aside.
- Remove the secondary air changeover valve vacuum hose.
- Unscrew the brake booster vacuum pipe at the top of the intake manifold.
- Disconnect the vacuum hose at the top of the intake manifold to the intake manifold pressure sensor.
- Slide the fuel tank vent valve up out of the bracket and set aside.
- Remove the fuel tank vent valve vacuum hose and fuel pressure regulator hose from the top of the intake manifold.
- Unscrew the fixing collar of the connecting pipe.
- Unscrew the mounting bolts on the bottom of the intake manifold and on the cylinder head cover.
- Remove the upper part of the intake manifold from the cylinder head cover.
- Engine 16V with a displacement of 1.8 and 2.0 liters: unscrew the cover of the ignition cable
- Disconnect the wire connector from the camshaft position sensor.
- For all engines: Disconnect spark plug connectors and remove from mountings.
- Remove the clamping clamps and crankcase ventilation hoses from the cylinder head cover.
- Unscrew the cylinder head cover from the cylinder head and carefully lift it up.
- Carefully remove the cover from the cylinder head - pay attention to the sealing rings!
- Remove gasket residue and clean sealing surfaces.
- Fit the cylinder head cover with new O-rings and new gaskets. Lubricate the gaskets with sealant.
- Install O-rings with a small amount of petroleum jelly in the cylinder head cover during installation so that they do not fall into the cylinder head when the cover is installed.
- When mounting, tighten the fixing bolts, starting from the middle of the cover, crosswise (8 Nm).
Camshaft removal
8 valve engine
- Remove the front toothed belt cover.
- It is impossible to dismantle the camshaft with the cylinder head installed by home means, because. during this work, the valves must be compressed with clamps. Valve clamps are sold in specialized stores. A new camshaft seal is also needed.
- Remove the cable duct on the cylinder head
- Remove the engine vent hose and unscrew the cylinder head cover.
- Turn the crankshaft to the ignition timing position of the 1st cylinder and then back ¼ turn. So all the pistons will be in the middle position, and the camshaft does not press on the pendulum levers.
- Loosen toothed belt and remove from camshaft pulley. To do this, turn the tension roller, counteracting the force of the spring, up until the holes on the tension roller match. Lock the idler pulley in this position with a suitable pin or drill.
- Unscrew the camshaft pulley. At the same time, press the camshaft with an open-end wrench in the opposite direction for the hexagon provided for this
- Remove the battery support see battery chapter.
- Remove the DIS ignition module (chapter «Ignition»).
- Remove the carrier plate underneath. Replace carrier plate O-ring, clean sealing surface.
- Unscrew the printed circuit board from the cylinder head.
- Cover the oil recirculation holes so that the stops do not fall in during installation.
- Press the valves down evenly
- Remove the camshaft from the housing.
- Remove the old camshaft seal. To do this, screw the self-tapping screw into the O-ring and remove it with pliers.
- If a new camshaft is installed, the pendulum arms must be replaced.
- Lubricate the sliding surfaces of the camshaft, stops and pendulum arms with MoS grease during installation2. Don't scare the details
- Lightly lubricate the new shaft seal and use a suitable pin to drive it into the camshaft housing.
- Before installing the camshaft, check if the crankshaft is 60 before TDC.
The photo shows the location of the intake (E) and graduation (A) valves in the cylinder head of an 8-valve engine.
Dismantling the camshaft bearing caps in the 16V engine: the arrows show where the numbers are located on the bearing caps and on the cylinder head. The dismantling of the bearing caps is carried out only in a certain sequence, see the text below.
- When applying a toothed belt, be sure to observe the valve timing.
- Tightening torques: printed circuit board on camshaft housing 8 Nm, bearing plate on camshaft housing 8 Nm (use a new gasket). Pulley on the camshaft - 45 Nm.
- After installing the camshaft, the engine can only be started after 30 minutes, see advice on the next page.
Camshaft dismantling
16V
- Set the engine to 60°until the ignition of the 1st cylinder.
- Loosen and remove toothed belt.
- Remove the cylinder head cover.
- Unscrew the camshaft pulleys. To do this, press the corresponding camshaft with an open-end wrench on the hexagon in front of the first cam.
- Loosen bearing caps 1, 3 and 5 first (intake camshaft), respectively 6, 8 and 10 (exhaust camshaft) half a turn and then one turn.
- Now alternately loosen bearing caps 2 and 4 crosswise (intake camshaft), respectively, 7 and 9 (exhaust camshaft) and take them off. The camshaft must be evenly released from the bearing housings.
- When installing, lubricate the sliding surfaces of the valve lifters and camshafts with MoS2 paste. On the sealing surfaces of the outer camshaft bearing caps (1 and 6) apply sealant (90350544).
- Install the camshafts so that both locking pins on the end faces of the camshafts face up. On 16V engines with a displacement of 1.8 and 2.0 liters, the pins must be turned slightly outward towards the intake, respectively, towards the exhaust manifold.
- Install bearing caps. In this case, the same code numbers must be opposite each other on the cover and the bearing seat.
- Screw the bearing caps of the corresponding camshaft from the inside out. Tighten the nuts step by step by 8 Nm.
- Lubricate the new camshaft O-rings and install with an appropriate tool.
- Screw the camshaft pulleys with new bolts (50 Nm + 60°+ 15P). Mount the camshaft pulley with cylinder recognition hoods on the exhaust camshaft. The valve timing markings must point forward.
- With 16V 1.8L and 2.0L engines, mount the camshaft pulleys so that the intake camshaft guide pin fits into the hole «IN» in his pulley. And the exhaust camshaft guide pin fits into the hole «EX» in his pulley.
- Apply toothed belt. Check valve timing.
- Tension the toothed belt and check the tension.
- After installing the camshafts, the engine can only be started after 30 minutes, see advice on the next page.
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