Note: If the engine is in the car, please do the following first:
- (a) Disconnect the negative battery cable
- (b) Remove the air filter and fuel injection parts (Section 3)
- (c) Disconnect all related electrical wiring, cables and hoses
- (d) Remove the distributor (Section 4)
- (e) Remove upper fan shroud and upper intake manifold
- (J) Disconnect the drive belts from the crankshaft pulley
- (g) Where used, remove the power steering pump leaving the hoses connected (Section 10)
- (h) Where used, remove air conditioner compressor leaving hoses connected (Section 11)
1. Remove nuts/bolts, lift valve cover. Remove fortification bars (where are used) and pads. Note the location of the cable holders.
2. Unscrew the nuts, remove the top cover of the timing belt and the gasket (photo). The bottom cover must not be removed.
3. Turn the engine so that the piston of cylinder No. 1 is at TDC (top dead center) during compression.
4. The notch in the crankshaft pulley must be aligned with the pointer on the oil pump housing or lower drive cover (photo). Alternatively, label '0' (TDC) on the flywheel/drive plate must be aligned with the pointer in the hole in the clutch housing.
5. No. 1 cylinder valves must be closed with cam lugs turned up.
6. On 10-valve engines, the recess on the back of the camshaft sprocket must be aligned with the top surface of the valve cover gasket (photo), (temporarily install a gasket if necessary).
7. On 20 valve engines, the recess on the back of the camshaft sprocket should align with the top edge of the cylinder head between the camshafts. Alternatively, the groove on the front of the sprocket should line up with the mark on the valve cover (temporarily installed).
8. Loosen the water pump mounting and adjustment bolts, turn the pump clockwise to reduce the tension of the timing belt (photo).
9. Remove the timing belt drive from the camshaft sprocket, move it to one side.
10. Unscrew the central bolt from the camshaft sprocket, blocking it with the method shown in photo 25.53 (Part A).
11. Remove the sprocket from the camshaft, remove the segment key.
12. Check that each bearing cap is numbered; if not, make a mark on the lid. Note that the covers are slightly offset and can only be installed in one direction.
13. It is important to follow the description exactly when removing the camshaft so that there is no danger of distortion.
10 valve engines
14. Unscrew the nuts of the bearing caps No. 1 and 3, and remove them (photo).
15. Loosen bearing cap nuts #2 and #4 evenly in diagonal sequence, then remove them.
16. Raise the camshaft and discard the oil seal (photo).
Engine with 20 valves
17. Turn off nuts of covers No. 2 and 4 bearings of an exhaust cam-shaft (pic. 1.14) and take them off.
18. Loosen bearing cap nuts Nos. 1, 3, and 5 evenly in a diagonal sequence, then remove the caps.
19. Raise the exhaust camshaft, disconnect it from the chain.
20. Turn off nuts of covers No. 7 and 9 bearings of an inlet cam-shaft (pic. 1.14), and remove them.
21. Loosen bearing cap nuts #6, 8, and 10 evenly in a diagonal sequence, then remove the caps.
22. Raise the intake camshaft, remove the chain.
All engines
23. Prepare a box with marked inner compartments to fold the pushers.
24. Remove the hydraulic tappets, place them upside down in the box to prevent oil from escaping.
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