- remove the battery;
- place the front of the car on supports and unscrew the protective shield (nine screws);
Fig. 52. Fastening the radiator grille
- unscrew the trim at the bottom of the radiator. It is secured in the places shown in Fig. 52;
- remove the right front wheel and the inner wheel arch trim (two screws);
- remove the poly V-belt;
Fig. 109. Left torque stop (on vehicles with manual transmission): 1, 2 — screws
- on vehicles with a manual transmission, loosen the screws of the right stop against rotation by two turns. This is screw 1 (Fig. 109) of the engine support and screws 2 of the subframe;
- on a car with an automatic transmission, loosen the middle screw of the right stop against rotation by two turns. Do the same on the vibration damper stop and the rack;
- On all vehicles, release the left strut from turning, but do not remove it;
Fig. 22. Fastening of air intake pipes: 1 — fastening bolts, 2 — plug, 3 — plug block, 4 — clamp, 5 — low-pressure hose
- remove the intake manifold according to Fig. 22. First remove the three fastening screws 1. Then remove the plug 3 from the sensor and on the same side remove the hose clamp 4. In the place indicated under the number 2, remove the multi-pin plug on the intake air sensor. On the left side there is a low pressure hose 5. Remove it;
- remove the air filter. To do this, disconnect the ventilation hose between the filter and the cylinder head cover. Hang the rubber ring on the right, lift the air filter out of the mount and remove it;
Fig. 54. Removing the throttle cable
- remove the throttle cable safety clip, disengage the cable from the lever and carefully set the cable back (see Fig. 54);
Fig. 110. Location of some connections: 1 - Power steering pressure switch; 2 - ground cable in the engine eye; 3 - Power steering high pressure line
- disconnect the following parts: plug 1 (Fig. 110) of the steering pressure switch, ground cable 2 from the engine eye and high pressure hose 3 of the auxiliary steering pump;
- disconnect the lambda probe plug from the engine mount;
- place a jack under the oil pan (with a wooden spacer between the head of the car jack and the engine/drive) and lift the power unit until the engine mount is unloaded;
Fig. 32. Right engine mount mounting locations
- remove the right engine mount. Fig. 32 shows how the mount bracket is secured. Always replace the self-locking nuts with new ones. Then remove the bracket;
Fig. 111. Left stop mounting locations
- with a manual gearbox installed, remove the stop from turning on the left side (Fig. 111). To remove the stop, the power unit must be raised;
- unscrew the auxiliary steering pump console mounting screws and remove the console;
- remove the generator suspension brackets;
- unscrew the middle and upper protective covers of the toothed drive belt after you have removed the drive belt tension roller;
- remove the spark plug wire ends. If you don't know what the wires are, mark the ends;
- unscrew the cylinder head cover (ten screws) and remove the sealing gasket;
- remove the spark plugs;
Fig. 59. Releasing the tension of the toothed drive belt: 1 - nut; 2 - tension roller
- loosen the toothed drive belt. To do this, unscrew nut 1 (see Fig. 59) and insert a suitable Allen key. Turn the belt tensioner in the direction of the arrow and tighten the roller in the new position. Remove the toothed drive belt, do not stain it with oil or break it if the belt is to be used again;
Fig. 45. Tool for holding camshaft gears
- loosen the mounting screws of both camshaft pulleys, holding the shafts from turning. The clamp shown in Fig. 45 is best suited for this purpose. Otherwise, insert a drift into one of the holes and carefully lock it against the cylinder head. Remove both pulleys, marking their location for subsequent installation;
Fig. 46. Sequence of loosening the camshaft bearing caps
- remove the camshafts. To avoid deformation of the shafts, loosen the bearing caps in a certain sequence (see Fig. 46). Accordingly, loosen the bearing cap nuts in the specified sequence by half a turn so that they can be unscrewed by hand. Mark the caps and remove them one by one. Carefully remove both camshafts and remove the radial sealing rings;
- remove the plate tappets one by one and place them in the sequence required for installation, or mark them.
Reinstall the camshafts. The camshafts are marked. The shaft for the intake valves has an additional cam on the end for the camshaft position sensor. A small amount of sealant is required to ensure a tight seal between the front camshaft bearing caps and the cylinder head.
Installation of camshafts is carried out in the following order:
Fig. 61. Sealing areas
- lubricate the areas on the cylinder head shown by the arrows in Fig. 61 with sealant for previous engines;
- thoroughly lubricate the bearing journals of the camshafts with oil and insert the shafts into the corresponding installation holes;
Fig. 62. Marking of camshaft covers
- install the camshaft bearing caps in numerical order. The marking is not quite conventional, as the first cap is marked "0" and is located on the exhaust side. Subsequent numbering is carried out as shown in Fig. 62. All numbers must be visible from the outside;
- screw in all the cover screws and tighten them by hand. Then tighten each corresponding pair of screws in the reverse order to that shown in Fig. 46 by half a turn. And again in the same order, tighten the screws, pair by pair, to a torque of 10 N·m. Finally, tighten all the screws again in the same sequence to a torque of 19 N·m. The bearing caps must remain parallel to the cylinder head surface during tightening;
- install new camshaft oil seals. Hammer the oil seal or use a piece of pipe with the diameter of the sealing ring. Screw an M10 screw and a large washer onto the pipe to press the seal onto the shaft. Lubricate the working edges of the seal well;
- fit the camshaft pulleys. The pulleys should rotate freely on the shafts;
Fig. 63. Gauge for adjusting valve timing
- Now you will need a gauge to adjust the valve timing. Install this gauge as shown in Fig. 63;
Fig. 64. Setting the crankshaft to top dead center (TDC)
- turn the crankshaft so that the cutout on the pulley is in the position shown in Fig. 64. This position corresponds to TDC;
Fig. 66. Placement of the toothed drive belt: 1 - belt, 2 - screw
- Lay the toothed drive belt in a counterclockwise direction on the three pulleys and the belt tensioner. First lay the belt on the crankshaft pulley, keeping the teeth engaged, lay it on the left around the lower guide roller and the toothed drive belt tensioner and pass the loop around the left camshaft pulley. Now, keeping the belt firmly engaged with the teeth of the camshaft pulley, lay it on the right pulley and finally pass it around the inside of the right running roller. Make sure that all the teeth provide perfect engagement. The belt laying is shown in Fig. 66. Now loosen nut 2, after which the belt tensioner will rush inward to provide the required tension;
- lock the camshaft pulleys from turning and tighten both screws to a torque of 68 Nm. The crankshaft should not turn. After tightening the screws, turn the crankshaft two revolutions - the shaft will again be at TDC;
- tighten the belt tensioner screw to a torque of 38 Nm;
- check that the gauge is still aligned according to Fig. 63 when the crankshaft is set to TDC. If not, loosen the corresponding camshaft pulley and move it slightly. Retighten the screw to 68 Nm;
- install the cylinder head cover on a new sealing gasket. Tighten the screws evenly around the circumference, first to 2 Nm, then to 7 Nm;
- screw in the spark plugs (15 Nm) and put the high-voltage wires on the spark plugs in accordance with the firing order of the cylinders;
- install the protective shields. Make sure that the middle cover is correctly positioned in the lower cover;
- install the drive belt pulley and tighten to 48 Nm;
- carry out all other work in the reverse order, taking into account the following tightening torques, N·m:
- middle stop screws
- from turning (automatic transmission) 120
- right stop against rotation on the subframe (mechanical)
- gearbox) 127
- right torque stop, middle screw (manual transmission) 48
- left anti-rotation stop (automatic transmission) 48
- front suspension 83
- wheel screws 130
After installation, test drive the vehicle to reactivate the fuel injection/ignition system control unit.
Note: If new camshafts were installed, the engine oil and oil filter must be replaced.
Camshaft seals
Replace the seals in the following order:
- provide access to the end of the camshaft with the drive gear so that it is possible to unscrew the pulley of the corresponding shaft and remove it;
- unscrew the front bearing cover and remove the sealing ring;
- apply sealant to the split surfaces of the front bearing cover and put the cover back on. Tighten the cover alternately on the right and then on the left to a torque of 10 N·m, and tighten it again from this position to a torque of 19 N·m;
- hammer a new seal onto the camshaft or press it in with a piece of pipe the diameter of the sealing ring. Screw an M10 screw and a large washer onto the pipe to press the seal onto the shaft. Lubricate the sealing edges well;
- place the pulley on the camshaft. The pulley should rotate freely on the shaft;
- install and tension the toothed drive belt as described in the relevant subsection.
Rear crankshaft oil seal
To replace the seal, remove the transmission, flywheel and clutch or drive pulley (automatic drive).
To remove the seal, drill two small holes in the ring. Insert two self-tapping screws and carefully remove the ring (using a screwdriver and pliers).
Fig. 112. Installing the seal
Lubricate the new sealing ring with oil along the sealing edge and the working surface of the crankshaft and press it into the crankcase. For pressing, use a disk, which is secured with two screws on the crankshaft flange. Uniformly tighten the screws to press in the radial sealing ring until the disk is adjacent to the crankshaft flange (Fig. 112).
After installing the seal, install the flywheel and tighten the screws evenly around the circumference to a torque of 112 N·m. Install the clutch (see the corresponding subsection) and reinstall the gearbox.