Withdrawal
Carry out an operation to reduce the pressure in the fuel system. To do this, let the engine run for 10 seconds with the fuel pump off. Remove the fuse to turn off the fuel pump (AV 2.003).
1. Remove the fuel pump power fuse.
2. Start the engine.
3. After the engine has stopped, start it again and let it run for approximately 10 seconds to use up the fuel contained in the fuel manifold to reduce residual fuel pressure in the system.
4. Disconnect the ground terminal of the electronic engine control unit (ECM) from the intake manifold.
5. Drain the engine coolant.
6. Disconnect the supply air temperature sensor connector (IAT).
7. Disconnect the crankcase ventilation hose from the valve cover.
8. Disconnect the air duct from the throttle body.
9. Disconnect the ignition coil connector.
10. Disconnect the coolant temperature sensor connector (CTS).
11. Disconnect the idle speed control connector (IAC).
12. Disconnect throttle position sensor connector (TP).
13. Remove the camshaft position sensor (SMR).
14. Turn away screws of the case of the air filter.
15. Remove the air filter housing.
16. Remove the screws from the top of the timing case.
17. Remove the top part of the timing case.
18. Align the ignition timing mark on the camshaft sprocket with the mark on the rear timing belt cover.
19. Remove the right forward wheel.
20. Remove the mudguard of the right front wheel.
21. Remove the accessory drive belt.
22. Disconnect the fuel supply line from the fuel manifold.
23. Remove the nut securing the power steering tube bracket.
24. Turn away a nut of the generator.
25. Remove a nut of fastening of an arm of the generator.
26. Remove the generator bracket.
27. Disconnect the vacuum brake booster hose at the intake manifold.
28. Disconnect any vacuum hoses that need to be disconnected and the electrical connector.
29. Disconnect the intake manifold absolute pressure sensor connector (MAP).
30. Remove the screw securing the crankshaft pulley.
31. Remove the crankshaft pulley.
32. Remove the screws from the bottom of the timing case.
33. Remove the lower part of the timing cover.
34. Slightly loosen the coolant pump mounting screws.
35. Loosen the timing belt tension by turning the coolant pump.
36. Remove the toothed belt.
37. Disconnect the crankcase ventilation tube from the camshaft housing.
38. Remove the valve cover with gasket.
Note. Avoid scratches, nicks, or other damage to the camshaft.
39. Remove the camshaft sprocket.
40. Remove the screws on the rear top of the timing case.
41. Disconnect the ignition wires from the spark plugs.
42. Disconnect the catalyst flange from the exhaust manifold flange.
43. Disconnect the oxygen sensor electrical connector.
44. Disconnect the heater pressure hose from the coolant distributor.
45. Disconnect the coolant hose connecting the expansion tank and throttle body.
46. Remove the front engine mount bolts.
47. Disconnect the accelerator cable from the throttle body and intake manifold.
48. Gradually loosen all screws securing the cylinder head in the sequence shown in the figure.
49. Remove the cylinder head screws.
50. Carefully remove the camshaft housing.
Note. When removing the cylinder head, be careful not to let engine oil or coolant enter the cylinders. Otherwise, engine damage may result.
51. Remove the cylinder head with the intake and exhaust manifolds installed on it.
52. Remove the cylinder head gasket.
Cleaning
Clean the surfaces of the cylinder head and block in contact with the gasket.
Check for deep scratches and nicks on the cylinder head and engine block gasket surface.
Clean the cylinder head screws.
Inspect the cylinder head for deformation.
Installation
1. Apply a continuous bead of 3 mm wide sealant to the sealing surface of the camshaft housing.
2. Install the cylinder head gasket.
3. Install the cylinder head along with the intake and exhaust manifolds.
4. Install the camshaft housing assembly.
5. Install the head cover screws in the sequence shown in the figure.
Tightening the cylinder head screws
6. Tighten the cylinder head screws in the sequence shown in the figure to a torque of 25 Nm.
7. Tighten the cylinder head screws 70°.
8. Tighten the cylinder head screws by 30°.
Connect the accelerator cable to the throttle body and intake manifold (AV 2.031).
10. Install and tighten the intake manifold support bracket screws to 25 Nm.
11. Connect the expansion tank coolant hose to the throttle body.
12. Connect the heater pressure hose to the coolant distributor.
13. Install the catalyst retaining nuts on the exhaust manifold flange.
Puff. Tighten the additional nuts securing the catalyst to the exhaust manifold to 40 Nm.
14. Connect the front oxygen sensor electrical connector.
15. Install the screws on the rear of the timing case cover and tighten them to 10 Nm.
Note. Be very careful not to scratch, nick or otherwise damage the camshaft. Such damage can impair the performance of the vehicle.
16. Install the camshaft sprocket.
17. Tighten the camshaft pulley screw to 45 Nm.
18. Connect the crankcase ventilation tube to the camshaft housing.
19. Align the mark on the camshaft sprocket with the mark on the top rear of the timing case.
20. Align the mark on the crankshaft sprocket with the mark on the bottom of the timing belt cover.
21. Install the toothed belt.
22. Check up a tension of a gear belt.
23. Tighten the screws on the bottom of the timing case to 10 Nm.
24. Install the crankshaft pulley.
25. Tighten the crankshaft pulley screws to 95 Nm.
26. Tighten the pulley screws an additional 30°+15°.
27. Connect vacuum hoses and electrical connectors.
28. Connect the brake booster hose to the intake manifold.
29. Connect the upper radiator hose to the ' thermostat housing.
30. Install the generator bracket.
31. Tighten the alternator bracket mounting nut to 25 Nm.
32. Install the alternator nut without tightening.
33. Connect the fuel supply line to the fuel manifold.
34. Install an additional accessory drive belt.
35. Tighten the screws of the upper part of the timing case to 10 Nm.
36. If necessary, install the A/C compressor belt.
37. Establish a mudguard of the right forward wheel.
38. Install the right front wheel.
39. Install the air filter housing.
40. Install the air filter housing by tightening the air filter housing screws to 8 Nm.
41. Connect the air duct to the throttle body.
42. Connect the ventilation tube to the timing cover.
43. Connect the intake air temperature sensor connector.
44. Install the CMP sensor.
45. Connect the coolant temperature sensor.
46. Connect the intake air temperature sensor connector valve.
47. Connect the sensor connector.
48. Connect the ignition coil connector of the ignition system.
49. Connect the multiport fuel injection harness connectors (SRVT).
50. Connect the oxygen sensor connector.
51. Connect the ground terminal of the engine control unit on the intake manifold.
52. Connect the negative battery cable.
53. Install the fuel pump fuse.
54. Fill the engine cooling system.