Special tool
 | Hammer with movable striker 205-047 (15011) |
 | Universal Flange Holding Wrench 205-072 (15030A) |
 | Valve Shim Pliers 303-196 (21107) |
 | Flywheel Locking Tool 303-204 (21168) |
 | Socket wrench for cylinder head bolts 303-392 (21167) |
 | Assembly stands 303-435 (21187) |
 | Support bracket for 303-435 303-435-06 (21031B) |
 | Support plate for 303-435-06 303-435-14 (21212) |
 | Spark Plug Wrench 303-499 (21202) |
 | Spark Plug Pliers 303-622 (21226) |
 | Adapter for 205-047 303-633 (21227) |
General equipment: Repair area crane.
Disassembly
All cars
1. Secure the engine to the assembly stand. Install special tools on the engine.
2. Drain the engine oil and remove the oil filter.
3. Remove the generator.
Cars without air conditioning
4. Disconnect the drive belt tensioner.
All cars
5. Remove the upper timing belt cover.
- Coolant pump pulley
- Intermediate pulley
- Valve timing belt cover
6. Disconnect the engine mount bracket.
7. Disconnect the fuel lines. Hose bracket.
8. Remove the cylinder head cover top plate (if equipped).
9.
CAUTION: The cylinder head cover gasket cannot be replaced individually. To avoid damaging the gasket, remove the cylinder head cover with it facing straight up.
CAUTION: When disconnecting the spark plug connector, do not pull on the wire. If necessary, remove the ignition coil to avoid bending the wire. Before removing, slightly rotate the spark plug connector to release the gasket.
CAUTION: Disconnect the spark plug connector using straight-line force only.
Remove the cylinder head cover.
- 1. Remove the high voltage wire clamp.
- 2. Disconnect the high tension wires from the spark plugs.
- For angled spark plug connectors, use special tool 303-622.
- 3. Disconnect the cylinder head temperature (CHT) sensor connector.
- 4. Unscrew and remove the nuts.
10. Remove the spark plugs. Use special tool 303-499.
11. Disconnect the crankshaft pulley/damper.
- 1. Connect the special tool using two bolts (M10x40 and M10x45) and corresponding nuts.
- 2. Unscrew the bolt.
- Hold in place using the special tool.
12. Disconnect the lower timing belt cover.
Timing Belt Tensioner with Cam
13. Loosen the tension and remove the timing belt. Remove the bolt.
14. Disconnect the timing belt tensioner.
Timing Belt Tensioner with Groove
15. Loosen the tension and remove the timing belt. Remove the bolts.
16. Disconnect the timing belt tensioner. Remove the bolts.
All cars
17. Remove the pulleys from the camshafts. Hold them in place using the special tool.
18. Remove the pulley from the crankshaft.
19. Disconnect the inner timing belt cover.
20.
NOTE: Tightening sequence.
NOTE: Keep the bearing caps in good order for future installation. Identification numbers are located on the outside surface of the camshaft bearing caps.
Remove the camshafts.
- Loosen each camshaft bearing cap bolt one turn until the camshaft is free.
- Remove the camshaft bearing caps.
- Remove the camshaft oil seal.
21.
NOTE: Keep the valve lifters in good condition for future installation.
Remove the valve lifters and valve adjusting shims. Use a special tool.
22. Disconnect the crankcase ventilation hose.
23. Remove the three lower intake manifold bolts from the cylinder block and disconnect the oil level dipstick tube. Disconnect the knock sensor (KS) connector from the clamp on the oil level dipstick tube.
24.
CAUTION: Before removing the cylinder head, it must be cooled to below 30°C.
CAUTION: Place the cylinder head on a soft supporting surface.
NOTE: Release sequence.
Disconnect the cylinder head. Unscrew the cylinder head bolts. Use a special tool.
25.
CAUTION: Do not damage the coolant pump impeller.
Remove the coolant pump.
26. Disconnect the thermostat housing and oil pressure switch.
27. Disconnect the crankcase ventilation hose and KS.
Cars manufactured up to 11.1999.
28.
CAUTION: Remove the oil pan by lifting it downward to prevent oil sludge or abrasive particles from entering the engine.
Disconnect the oil pan.
Cars manufactured since 12.1999.
29. Drain the engine oil and remove the oil pan bolts (shown with the engine installed in the vehicle).
- 1.Remove the drain plug.
- 2. Unscrew the oil pan bolts.
30.
CAUTION: To avoid damaging the sealing surfaces, use only the specified special tool to remove the oil pan. Do not use a chisel or screwdriver for removal.
Disconnect the oil pan.
- 1. Install the special tools and secure them to the oil pan.
- 2. After several blows, separate the oil pan from the cylinder block.
All cars
31. Disconnect the oil inlet pipe and the oil pump together with the gasket. Remove the oil seal from the oil pump onto a flat surface.
Cars with manual transmission.
32.
CAUTION: Loosen the bolts two turns so that the clutch pressure plate is released.
Using a special tool, lock the flywheel and remove the clutch.
33. Disconnect the flywheel (locked with a special tool).
Remove the central bolt of the engine roll limiter (right front axle shaft).
34. Disconnect the drive disk (locked with a special tool).
All cars
35. Remove the crankshaft position sensor (CSP).
36. Disconnect the crankshaft rear oil seal housing and the crankshaft position sensor (CPS) support.
37. Disconnect the cylinder block together with the crank mechanism from the assembly stand (incomplete cylinder block). Disconnect the special tools from the cylinder block.