Disconnect from the throttle pipe 5 (see fig. 2-6) hoses 4 for supplying and discharging coolant, as well as a tube 2 for crankcase ventilation at idle. Remove the throttle pipe with gasket by unscrewing the nuts securing it to the receiver 6.
Remove hose 1 (pic. 2-8) fuel pipe by disconnecting it from the fuel rail 2. Unscrew five nuts, remove the receiver 6 (see fig. 2-6) with gasket and engine screen bracket.
Disconnect the wiring harness from the injectors, remove the fuel rail 2 (pic. 2-8), having unscrewed two bolts 3 fastening to an inlet pipe.
Pic. 2-8. Removing the elements of the power system:
1 - fuel pipeline hose;
2 - fuel rail;
3 - bolt.
Remove the starter shield.
Turn away nuts and remove an inlet pipe.
Loosen nuts 7 (pic. 2-9) and remove the screen 6. Unscrew the nuts 1, 4 and remove the exhaust manifold 2.
Pic. 2-9. Removing the exhaust manifold:
1 - nut;
2 - exhaust manifold;
3 - hairpin;
4 - nut;
5 - washer;
6 - collector screen;
7 - screen fastening nut.
On the left side of the engine, remove the ignition coil, on the right - the knock sensor. Remove the conditioner compressor following the recommendations stated in subsection «Air conditioning system».
Loosen nuts 8 (see fig. 2-63) turn out a bolt 5 and remove a belt 7 of a drive of auxiliary units. Remove the alternator, alternator bracket, tensioner.
Remove the coolant pump.
Remove bolts 2 (see fig.2-10) and remove the pump 9 of the power steering.
Pic. 2-10. Removing the oil filter:
1 - plate;
2 - a bolt of fastening of the hydraulic booster pump;
3 - a bolt of fastening of an arm of the oil filter;
4 - sealing ring;
5 - gasket;
6 - oil filter bracket;
7 - fitting;
8 - oil filter;
9 - power steering pump.
Using a tool, unscrew and remove the oil filter 8 with the gasket. Turn away bolts 3 and remove an arm 6 of the oil filter.
Remove the coolant outlet pipe and the coolant outlet pipe to the heater from the cylinder head.
Remove the crankshaft damper by securing the flywheel with retainer A.60330/R (pic. 2-11) and loosen the nut with a wrench.
Unscrew sensor 11 (pic 2-12) oil pressure indicator light. Remove the crankcase breather cap, crankcase, oil pump drive gear retainer, oil pump. Remove the oil separator drain tube retainer and remove the crankcase ventilation oil separator.
Remove the cylinder head cover, with engine screen and accelerator cable brackets. Remove the camshaft drive cover. Loosen the camshaft sprocket and oil pump drive shaft bolts.
Pic. 2-11. Flywheel Removal:
1 key;
2 - flywheel;
3 - flywheel mounting bolt;
4 - washer;
5 - retainer A.60330/R to keep the flywheel from turning;
6 - front cover of the clutch housing.
Hydraulic tensioners and oil supply pipes of two options are installed on the engine. Tubes and hydraulic tensioners are not interchangeable.
For the first option: unscrew the tube fitting 4 (pic. 2-12) oil supply and disconnect it from the tensioner 6. Unscrew the nuts securing the tensioner to the cylinder head, remove it and, unscrewing the bolt, remove the shoe 2 of the chain tensioner 1.
Unscrew the fitting of the oil supply pipe 4 from the adapter 9, remove the pipe.
Unscrew bolt 10, remove adapter 9 and sealing washers.
Pic. 2-12. Elements of the chain tension mechanism:
1 - chain;
2 - tensioner shoe;
3 - tube for supplying oil to the tensioner (option 2);
4 - oil supply pipe to the tensioner (option 1);
5 - tube fastening bolt;
6 - chain tensioner;
7 - camshaft sprocket;
8 - calmer;
9 - adapter;
10 - tube mounting bolt;
11 - oil pressure warning lamp sensor;
12 - sprocket of the oil pump drive shaft;
13 - crankshaft sprocket.
For the second option (installed from 08.2008): unscrew the bolt 5 fastening the tube 3 for supplying oil to the tensioner 6, remove the sealing washers.
Unscrew the bolt 10 fastening the tube 3 to the cylinder block, remove the tube and sealing washers.
Remove the sprockets 7 and 5 of the oil pump drive, camshaft and chain.
Loosen the stud nuts 4 (pic. 2-13). Remove the camshaft bearing housing. Having unscrewed the nuts of the studs 4 and, having removed the thrust flange 1, carefully, so as not to damage the surface of the bearing housing supports, remove the camshaft.
Pic. 2-13. Removing the thrust flange of the camshaft:
1 - thrust flange;
2 - camshaft;
3 - bearing housing;
4 - stud for fastening the thrust flange.
Turn away bolts of fastening of a head of cylinders and remove it.
Remove thrust flange 1 (pic. 2-14) oil pump drive roller and remove the roller from the cylinder block.
Pic. 2-14. Removing the oil pump drive shaft:
1 - thrust flange;
2 - flange fastening bolt;
3 - oil pump drive roller;
4 - key.
Pic. 2-15. Removing the crankshaft sprocket with a universal puller.
Using a universal puller, remove the sprocket from the crankshaft (pic. 2-15).
Loosen the nuts of the connecting rod bolts, remove the connecting rod caps and carefully remove the pistons with connecting rods through the cylinders. Mark the piston, connecting rod, main and connecting rod bearing shells in order to install them in their original place during assembly.
Warning. When removing the connecting rod and piston group, it is not allowed to press out the connecting rod bolts from the connecting rods.
Install retainer 5 (see fig. 2-11), unscrew the bolts 3, remove the washer 4 and the flywheel from the crankshaft. Remove the front clutch housing cover.
Using a special puller, remove the bearing of the input shaft of the gearbox from the socket in the crankshaft (pic. 2-16).
Pic. 2-16. Pressing the gearbox shaft bearing out of the crankshaft.
Remove the crankshaft oil seal holder.
Turn away bolts of covers of radical bearings, remove them together with the bottom loose leaves, remove a cranked shaft, top loose leaves and persistent half rings on a back support.