Note: Cover the fenders to prevent damage to the paintwork.
To avoid damage, disconnect electrical connectors carefully, holding the connector by its body.
To prevent damage to the cylinder head, wait until the coolant temperature drops below 38°C before releasing the cylinder head bolts.
Label all wire harnesses and hoses to avoid confusion during installation. Also make sure they do not touch other wires or hoses or come into contact with other parts.
1. Relieve fuel pressure.
2. Drain the engine coolant.
3. Remove the air cleaner housing.
4. Remove the Fuel Vapor Absorber tank (EVAP) hose A and the coolant bypass hoses B.
5. Remove the upper radiator hose A and the lower radiator hose B.
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6. Remove the heating system hoses.
7. Remove the drive belt.
8. Remove the intake manifold.
9. Remove the exhaust manifold.
10. Remove the engine wire harness connectors and wire harness retainers from the head.
- Four fuel injector connectors.
- Connector of sensor 1 of coolant temperature (ECT).
- Camshaft position sensor (CMP) connector.
- Oil pressure sensor connector.
- Knock sensor connector.
- Exhaust Gas Recirculation (EGR) valve connector.
11. Remove the fuel rail.
12. Remove the air cleaner housing mounting bracket A, ground wire B and wire harness retainer mounting bolt C, then remove the wire harness retainer from its bracket.
13. Remove connecting hose A, coolant bypass hose B, positive crankcase ventilation (PCV) hose C.
14. Remove the cylinder head cover.
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15. Set piston #1 to top dead center (TDC). The "UP" mark on the camshaft sprocket should be at the top, and the top dead center (TDC) marks on the sprocket should be aligned with the top edge of the cylinder head.
16. Remove the generator bracket mounting bolt and loosen the generator mounting bolt.
17. Remove the idler pulley.
18. Remove the water pump pulley.
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19. Remove the crankshaft pulley.
20. Disconnect the crankshaft position (CKP) sensor connector, then remove the harness clamps.
21. Support the engine with a 300x300x25 mm wooden beam and a jack under the oil pan.
Note: Do not place the jack under the center of the oil pan to avoid damaging it.
22. Remove the ground cable, then remove the upper bracket.
23. Avoid contact between the generator and the timing chain housing. Remove the timing chain housing.
24. Apply mark A to the drive chain sprocket and to the timing chain.
25. Install the crankshaft pulley into place without tightening.
26. Lubricate the sliding surface of the timing chain tensioner slider with engine oil through the oil return hole in the cylinder head.
27. While holding the crankshaft pulley, install socket wrench A onto the camshaft sprocket bolt.
28. Turn the camshaft counterclockwise to compress the timing chain tensioner, then install the 6x1.0mm bolt B into hole C on the engine block through the timing chain tensioner.
Note: The torque must exceed 44 Nm when turning the camshaft.
Do not turn the camshaft counterclockwise.
29. Holding the camshaft with an open-end wrench, remove the camshaft sprocket.
30. Remove the timing chain guide mounting bolt.
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31. Remove the cylinder head cover bolts. To avoid warping, loosen the bolts sequentially by 1/3 of a turn each and repeat these steps until all the bolts are loosened.
32. Remove the cylinder head.