Note:
- To avoid warping of the cylinder head, do not remove it when the coolant temperature is above 38°C.
- Label all wires and hoses before disconnecting. Make sure they do not come into contact with other wires, hoses or parts.
1. Relieve residual fuel pressure,
2. Drain the coolant.
3. Remove the air filter assembly.
- A) Disconnect the sensor connector.
- b) Turn out bolts.
- V) Remove the air filter.
A - plug
B - bolt
C - air filter.
4. Disconnect the EVAP filter connectors "A", throttle body "IN", coolant bypass hose "WITH" and cleaning hose "D".
5. Remove the upper and lower radiator hoses.
6. Remove heater hoses.
7. Remove the accessory drive belt.
8. Remove the intake manifold.
9. Remove the exhaust manifold.
10. Disconnect the wiring harness connectors and remove the retainers from the cylinder head..
11. Remove the fuel manifold.
12. Remove the wire holder "A", ground wire "IN", wire clamp "WITH", coolant bypass hose "D" and wiring harness "E".
13. Remove connecting tube "A" and coolant bypass hose "IN".
14. Remove the cylinder head cover.
15. Turn out bolts of fastening of an arm of the generator and weaken a bolt of fastening of the generator.
16. Remove the intermediate roller.
17. Set the piston of the first cylinder to TDC. At the same time, the label "UP" on the crankshaft sprocket must point upwards, and the recesses on the sprocket must lie in the plane of the cylinder head.
Removal and installation of a head of the block of cylinders.
1 - bolts of fastening of a head of the block of cylinders,
2 - thermostat housing,
3 - thermostat,
4 - valve of the recirculation system,
5 - gasket,
6 - ring seal,
7 - locating pin,
8 - cylinder head gasket.
18.Check that the pulley notch lines up with the bench mark.
19. Remove the coolant pump pulley.
20. Remove the crankshaft pulley.
21. Disconnect the crankshaft position sensor connector and clips.
22. Jack up the engine. Place a block of wood between the heel of the jack and the engine.
Note: Do not place the jack in the center of the oil pan to avoid damage to the pan.
23. Remove the ground wire and front engine mount bracket (see section "Timing chain").
24. Remove the generator. Remove the timing chain cover.
25. Mark target and camshaft sprocket.
26. Temporarily, install the crankshaft pulley.
27. Apply engine oil to the contact surface of the tensioner through the oil return hole in the cylinder head.
28. Fix the crankshaft pulley and install the key on the camshaft sprocket bolt.
29. Turn the camshaft clockwise until the chain tensioner is compressed, then install the M6x1.0 mm bolt into the hole in the cylinder block through the tensioner shoe.
Note:
- The torque when turning the camshaft bolt must not exceed 56 Nm.
- Do not turn the camshaft counterclockwise.
30. Fix the camshaft with a 27 mm wrench, remove the bolt and remove the sprocket.
31. Turn out a bolt of fastening of a directing chain.
32. Turn out bolts of fastening of a head of the block of cylinders. To prevent warping of the cylinder head, turn the bolts alternately ⅓ of a turn per pass in the sequence shown in the figure.
33. Remove the cylinder head.