Drain the coolant from the cylinder block and radiator
Using a 5 mm socket wrench, unscrew the two nuts and remove the top protective cover (fig. 1).
Remove upper intake manifold assembly.
Disconnect the following wires and connectors:
- - throttle position sensor connector;
- - idle speed control valve connector;
- - connector for the electro-pneumatic valve of the intake manifold geometry change system (ACIS);
- – connector for the electropneumatic valve of the fuel pressure control system;
- - diagnostic connector from the bracket on the auxiliary air valve.
Detach:
- - brake booster vacuum hose from ACIS auxiliary air supply valve;
- - crankcase ventilation system hose from the crankcase ventilation system valve on the rear cylinder head;
- - clamp and ground wire from the ACIS auxiliary air supply valve;
- - ground wire from the top of the intake manifold;
- - clamp the vacuum hose from the fuel pipe;
- - two coolant bypass hoses from the throttle body (Fig. 2);
- - hose for supplying additional air from the throttle body (Fig. 3);
- - two power steering air hoses from the top of the intake manifold (Fig. 4);
- - two vacuum hoses from the tubes on the block head plate;
- - vacuum hose from the fuel pressure regulator (Fig. 5).
Remove the two bolts and remove the engine bracket #1.
Remove the two bolts and remove the upper intake manifold strut (fig. 6).
Using an 8mm socket wrench, remove the two bolts and two nuts and remove the upper intake manifold assembly and gasket (See Fig. 7).
Remove the intake manifold assembly (see Fig. 8).
Disconnect the six injector connectors.
Detach:
- – inlet fuel hose from the fuel filter;
- – fuel return hose from the fuel return pipe;
- - heater hose from the intake manifold.
Remove nine bolts, two nuts, remove the two washers, intake manifold, fuel manifold and injector assemblies.
Remove the cooling system outlet pipe by unscrewing the two bolts, two nuts and disconnecting the coolant bypass hose, then remove the two gaskets.
Remove the ignition coils.
Remove the spark plugs.
Remove the timing belt.
Remove the camshaft pulleys and idler pulley (Fig. 9).
Remove the #3 timing belt cover by unscrewing the 6 bolts and disconnecting the three wiring clips.
Remove the protection of the engine wiring from the flywheel side.
Remove the two nuts and disconnect the wiring protection from the rear cylinder head and the cooling system inlet.
At the rear of the engine, remove the five nuts and disconnect the two wire guards from the rear cylinder head.
At the front of the engine, unscrew the two nuts and disconnect the wiring protection from the front cylinder head.
Remove the bolt and disconnect the coolant supply pipe from the inlet pipe of the cooling system, remove the O-ring from the pipe.
Remove the rear heat shield by removing the three bolts.
Remove the six nuts and remove the rear exhaust manifold with gasket.
Remove the front heat shield by removing the three bolts.
Remove the six nuts and remove the front exhaust manifold with gasket.
Remove the camshaft position sensor.
Remove the cylinder head covers by unscrewing the eight mounting bolts.
Removing cylinder heads
Using an 8mm wrench, remove the hexagon socket head bolts on each cylinder head (fig. 10).
Evenly loosen and remove the two nuts and eight cylinder head bolts in several passes, in the sequence shown in Figure 11.
WARNING Incorrect order of unscrewing the bolts can lead to deformation of the head of the block.
Remove the cylinder head from the guide pins on the cylinder block and place it on a workbench with a piece of wood and a rag.