ADP and AHL engines (SOHC)
Withdrawal
1. Remove the engine top cover.
2. Remove the clamp and disconnect the crankcase ventilation hose from the valve cover. Remove the sealing ring.
3. Loosen and remove the upper timing belt cover as described in paragraph 4.
4. Turn away nuts of fastening of a valvate cover. Note the position of the inner timing belt guide and small bracket. Remove reinforcing bars.
5. Remove cover and gasket.
6. Remove the oil separator from the cover.
Installation
7. Clean the mating surfaces and apply the appropriate sealant to the upper edges of the semi-circular cutout in the cylinder head
9. At the front of the cylinder head, apply a suitable sealant at the two contact points of the camshaft support cover with the cylinder head.
10. Carefully lay the gasket on the cylinder head, lay the cover along with the reinforcing strips and small brackets. Tighten the nuts gradually and evenly to the prescribed torque.
11. Install the upper timing belt cover and secure with clips.
12. Attach the crankcase ventilation hose with a new O-ring and secure with a clamp.
13. Install the engine top cover.
ADR, AFY, APT and APW engines (DOHC)
Withdrawal
14. Remove the engine top cover.
15. Switch off ignition, disconnect high-voltage wires from candles of the first and second cylinders. Disconnect the wire from the ignition coil installed to the valve cover.
16. Loosen the nut and disconnect "mass" wire from the ignition coil.
17. Turn away nuts of fastening, remove the ignition coil together with high-voltage wires. Remove the gasket.
18. Unfasten and remove the upper timing belt cover.
19. Remembering the position of the heat shield, unscrew the nuts and bolts from the valve cover. Remove the heat shield, remove the cover from the cylinder head. Remove the main gasket and spark plug center gasket (pic. 7.19, e-c).
Installation
20. Clear mating surfaces of a cover and a head of cylinders, establish an oil deflector.
21. At the rear of the head, apply a suitable sealant to the two contact points of the hydraulic tensioner/camshaft adjuster with the cylinder head (pic. 7.21). Similarly, at the front of the cylinder head, apply sealant to the top contact points of the double cylinder head bearing cover.
22. Carefully lay the gaskets on the cylinder head. Install oil baffle plate and install valve cover with heat shield (pic. 7.22). Gradually tighten the nuts and bolts to the prescribed torque.
23. Install the upper timing belt cover and secure with clips.
24. Install the ignition coil with a new gasket, making sure that the high-voltage wires are put on the candles to the stop. Tighten the fastening nuts to the prescribed torque.
25. Install the engine top cover.
AEB and AJL engines (DOHC Turbo)
Withdrawal
26. Remove the engine top cover.
27. Loosen the clamp securing the crankcase ventilation hose to the ventilation tube at the front of the engine. Loosen the mounting bolts (located on the riveted cover and cylinder head) and disconnect the ventilation tube from the hose. Take the handset aside.
28. Loosen and remove the timing belt top cover.
29. Disconnect the wiring from the ignition coils on top of the valve cover.
30. In front of the valve cover, unscrew the bolt and disconnect "mass" the wire.
31. Remove the mounting bolts and remove the ignition coils from the riveted cover, while disconnecting them from the spark plugs. Remove o-rings, replace if necessary.
32. Turn away nuts, remove a valvate cover from a head of cylinders. Remove the main gasket and spark plug center gasket.
Installation
33. Clean the mating surfaces of the cover and head, install the oil separator.
34. At the rear of the cylinder head, apply a suitable sealant to the two points of contact between the hydraulic tensioner and the cylinder head. Similarly, at the front of the cylinder head, apply sealant to the two contact points of the double camshaft bearing cover on the cylinder head.
35. Lay both gaskets on the cylinder head, install the valve cover with a heat shield. Tighten the nuts and bolts to the specified torque.
36. Install each ignition coil with o-rings, making sure they are properly connected to the high voltage wires. Tighten the mounting bolts to the prescribed torque.
37. Connect the wiring to the ignition coils.
38. Install the wire "masses" and tighten the bolt.
39. Install the timing belt top cover.
40. Attach the crankcase ventilation tube to the hose, attach the tube to the valve cover and tighten the bolts.
41. Install the engine top cover.
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