1. Disconnect the wire from the terminal «minus» battery.
2. Press the latch...
3.... and disconnect the wiring harness connector from the electro-hydraulic valve of the exhaust camshaft.
4. Disconnect the harness connector from the electro-hydraulic valve of the intake camshaft in the same way.
5. Remove the air filter housing (see «Removal and installation of the air filter and an air duct»).
6. Remove the timing belt from the camshaft pulleys (see «Replacing the timing belt»).
7. Remove the cylinder head cover (see «Replacing the cylinder head cover gasket»).
8. While holding the exhaust camshaft from turning with a wrench, unscrew the cap of the toothed pulley mounting bolt...
9.... and remove the plug.
10. Similarly turn out and remove a plug of a camshaft of inlet valves.
11. While holding the exhaust camshaft from turning, unscrew the toothed pulley mounting bolt...
12.... and remove the pulley.
13. Similarly turn out a bolt and remove a gear pulley of a camshaft of inlet valves.
14. Replace sealing gaskets of plugs of bolts of fastening of gear pulleys of camshafts irrespective of their condition.
15. Install a jack or support under the crankcase.
16. Turn out a bolt...
17.... and unscrew the two nuts securing the right suspension support of the power unit to the body side member.
18. Turn out three bolts of fastening of a support to an arm of the engine...
19.... and remove the support.
20. Turn out a bolt of fastening of the holder of the pipeline of the hydraulic booster to an arm of a support.
21. Turn out three bolts of fastening of an arm to the engine.
22. Remove the bracket.
23. Turn out three top bolts...
24.... and one lower bolt for fastening the upper cover of the timing gear.
25. Overcoming resistance of clamps, disconnect the holder of a plait of wires from the top casing.
NOTE: This is the location of the harness retainer clips.
26. Remove the upper drive belt cover.
27. Turn out bolts of fastening of a forward cover of bearings of camshafts to a head of the block of cylinders...
28.... and remove the cover.
29. Clean the mating surfaces of the cylinder head...
30.... and the front cover of the camshaft bearings.
31. Remove the intake and exhaust camshaft seals from the sockets in the cylinder head.
32. Replace the camshaft seals regardless of their condition.
33. Loosen the bolts securing the exhaust camshaft bearing caps in the sequence shown in fig. 5.5.
34. Finally unscrew the bolts, remove the camshaft bearing caps...
35.... and remove the exhaust camshaft.
36. Similarly, in the sequence shown in fig. 5.5, unscrew the bolts securing the intake camshaft covers, remove the covers...
37.... and then the intake camshaft.
WARNING: The camshaft bearing caps are machined together with the beds in the cylinder head, so they cannot be depersonalized. Bearing serial numbers are stamped on the covers. Cast numbers are technological for the lid casting process and do not serve as a guideline for lid installation. Install the camshaft bearing caps in strict accordance with the markings on them.
38. Inspect the camshafts. Bearing surfaces...
39....and the cams must be well polished and without damage. On the working surfaces of the necks, scoring, nicks, scratches, aluminum enveloping from the bearing seats in the block head are not allowed. If there are signs of seizing, overheating, deep scratches or wear in the form of a cut on the working surfaces of the cams, replace the shafts.
WARNING: Grinding the camshaft cams to eliminate stepped wear is prohibited, since changing the size of the cam profile will disrupt the valve timing.
40. In workshops equipped with special tools and fixtures, you can check the radial runout of the camshaft journals. If the runout is more than 0.02 mm or the journals are misaligned, replace the shaft, as it cannot be edited.
41. Lubricate the camshaft beds with clean engine oil and lay the camshafts in them.
42. Establish covers of bearings of camshafts and evenly tighten bolts of their fastening, passing from a bolt to a bolt through a turn, in the sequence shown in fig. 5.6, with the moment specified in Appendix 1.
43. Press the seals of the exhaust and intake camshafts into the sockets of the cylinder head (see «Replacing camshaft seals»).
44. Install the remaining parts removed in the reverse order of removal.
45. Adjust valve clearances (see «Valve clearance adjustment»).