Engine Components - Removal, Replacement And Installation
- Ignition, Engine Control (B4204T2 CVVT; 2000)
- Engine Mechanical (B4204T2 CVVT; 2000)
- Camshaft seals, replacing
- Notes
- Preparations
- Removing timing gear covers
- Installing the lifting beam and the lifting hook
- Removing the right-hand engine mounting
- Position the engine according to the marking
- Removing the timing belt
- Removing the timing gear pulley
- Replacing the camshaft seal
- Secure the crankshaft position
- Installing camshaft timing gear pulleys
- Installing the timing belt
- Tightening timing gear pulley
- Check
- Installing the timing covers
- Installing the right-hand engine mounting
- Finishing
- Checking work
- Crankshaft seal rear, replacing
- Cylinder head/gasket, replacing
- Notes
- Preparation
- Coolant, draining
- Exhaust manifold, removing
- Starter motor, removing
- Fuel line, draining
- Fuel line, removing
- Components, removing
- Cable harness, exposing
- Inlet pipe, removing
- Timing belt pulley, removing
- Coolant pump's inlet pipe, disconnecting
- Camshaft cover and cylinder head, removing
- When replacing or working on the cylinder head
- Gasket face, cleaning
- Installing the cylinder head
- Notes
- Aligning the crankshaft
- When replacing or working on the cylinder head
- Installing the cylinder head
- Valve depressors and camshafts, installing
- Camshaft cover, installing
- Coolant pump's inlet pipe, installing
- Front camshaft seal, installing
- Camshafts' timing belt pulley, installing
- Installing engine mounting
- Right engine mount, installing
- Finishing
- Installing components
- Inlet pipe, installing
- Components, installing
- Fuel line, installing
- Exhaust manifold, installing
- Starter motor, installing
- Checking performed work
- Engine replacement, transferring components
- Overview
- Notes
- Starter motor, removing
- Transmission, removing
- Carrier plate, removing
- Engine on mounting stand, installing
- Engine components left-hand side, transferring
- Engine components exhaust side, transferring
- Engine components air intake side, transferring
- Carrier plate, installing
- Transmission, installing
- Starter motor, Installing
- Removing turbocharged engines with the transmission
- Overview
- Notes
- Radiator and engine, draining coolant
- Removing the left-hand side drive shaft nut
- Removing the front and rear splash guards under the engine
- Removing the lateral strut
- Removing the front-rear member
- Removing the down pipe from the exhaust manifold
- Removing the rear engine mounting
- Removing the front engine mounting
- Removing the poly V-belts
- Removing the air conditioning (A/C) compressor
- Removing the oil pressure sensor and generator (GEN) connectors
- Removing the right-hand drive shaft from the transmission
- Removing the left-hand side cover
- Removing the left-hand side drive shaft assembly
- Automatic transmission: Disconnect the transmission oil pipes
- Draining the fuel injection system
- Removing the battery and battery shelf
- Removing the air cleaner (ACL)
- Disconnect the battery positive and negative leads
- Removing the gear selector mechanism cables
- Removing the vacuum hose from the canister purge (CP) valve
- Removing hoses from the turbocharger (TC)
- Removing the throttle cable
- Removing the cover, the mounting and the connectors
- Removing the fuel line from the engine
- Removing the cable harness
- Removing the coolant hoses
- Removing the heater hoses from the engine connection
- Removing the power steering pump from the engine
- Place the hood in the service position
- Removing the engine with the transmission
- Replace the engine mountings
- Replacing the cover on top of the engine
- Replacing the oil pump and front crankshaft seal
- Replacing the timing belt
- Notes
- Removing the auxiliaries belt
- Removing the timing covers
- Installing the lifting beam and lifting hook
- Removing the right-hand engine mounting
- Position the engine according to the marking
- Removing the timing belt
- Tensioning the tensioner pulley and the idler pulley
- Removing the splash guards under the engine
- Removing the timing belt (at the bottom)
- Installing the timing belt
- Check
- Installing timing covers
- Installing the right engine mounting
- Finishing
- Checking work
- Turbocharged engine assembly with the transmission, installing
- Overview
- Notes
- Place the hood in the service position
- Engine assembly with transmission, installing
- Manual transmissions: Installing the gear selector mechanism cables
- Automatic transmission: Installing the gear selector mechanism cables
- Engine mounting on transmission side, installing
- Hoses and wiring, routing and connecting
- Fuel hose, routing and connecting
- Charge air hose from the turbocharger (TC), upper hose, installing
- Air conditioning (A/C) compressor on engine, installing
- Connectors, connecting
- Drive shaft right-hand in transmission, installing
- Engine mounting rear, installing
- Engine mounting front, installing
- Front-rear member, installing
- Front exhaust pipe on exhaust manifold, installing
- Automatic transmission: Installing the oil pipes
- Drive shaft left-hand side, installing
- Lateral strut, installing
- Engine splash guards, installing
- Front wheel, installing
- Wiring, installing
- Coolant hoses, installing
- Heater hoses, installing
- Air cleaner (ACL), installing
- Battery, installing
- Throttle cable and the air intake hose on the throttle body (TB), securing
- Power steering pump, installing
- Poly V-belts, installing
- Coolant, filling
- VVT-unit, replacing/adjusting
- Replacing camshaft seal (retaining ring) front side
- Replacing engine mounting bolsters
- Replacing flange plate
- Replacing rearmost crankshaft retaining ring
- Replacing the camshaft seals
- Notes
- Preparations
- Removing the timing covers
- Installing the lifting beam and lifting hook
- Removing the right-hand engine mounting
- Position the engine according to the marking
- Removing the timing belt
- Removing the timing gear pulley
- Replacing the camshaft seal
- Secure the crankshaft position
- Installing the camshaft timing gear pulley
- Installing the timing belt
- Tightening the timing gear pulley
- Check
- Installing timing covers
- Installing the right engine mounting
- Finishing
- Checking work
- Replacing the cylinder head and gasket
- Notes
- Preparation
- Draining the coolant
- Separating the exhaust system
- Removing the manifold and turbocharger (TC)
- Removing the starter motor
- Draining the fuel line
- Removing the fuel line
- Removing components
- Exposing the cable harness
- Removing the intake manifold
- Installing the lifting beam and lifting hook
- Removing the right-hand engine mounting
- Position the engine according to the marking
- Removing the timing belt
- Removing the timing gear pulley
- Releasing the intake pipe for the coolant pump
- Removing the camshaft cover and cylinder head
- When replacing or working on the cylinder head
- Cleaning the gasket face
- Installing the cylinder head
- Notes
- Aligning the crankshaft
- When replacing or working on the cylinder head
- Installing the cylinder head
- Installing the valve lifters and camshafts
- Installing the camshaft cover
- Installing the intake pipe for the coolant pump
- Installing the front camshaft seal
- Installing the camshaft timing gear pulley
- Installing the timing belt
- Tightening the timing gear pulley
- Check
- Installing the right engine mounting
- Finishing
- Installing the intake manifold
- Installing components
- Installing the fuel line
- Installing the exhaust manifold
- Assembling the exhaust system
- Installing the starter motor
- Checking work
- Replacing toothed (timing) belt
- Notes
- Remove auxiliaries belt
- Remove upper timing gear covers
- Install lifting beam and lifting lug
- Remove engine mounting on timing gear side
- Remove lower timing gear cover
- Remove engine bracket
- Align timing gear and crankshaft according to the markings
- Remove timing belt at the top side
- Check idler pulley
- Remove the engine splashguards
- Remove timing belt at lower side
- Install timing belt at lower side
- Install cover plates
- Install new timing belt and tensioner pulley
- Adjusting timing belt tension
- Check timing belt tension
- Install engine bracket
- Install timing gear covers
- Install auxiliaries belt
- Install engine suspension on timing gear side
- Camshaft seals, replacing
- Ignition, Engine Control (B4204T3 (Ca) (Us); 2001-2003)
- Engine Mechanical (B4204T3 (Ca) (Us); 2001-2003)
- Camshaft seals, replacing
- Crankshaft seal rear, replacing
- Cylinder head/gasket, replacing
- Engine replacement, transferring components
- Removing turbocharged engines with the transmission
- Replace the engine mountings
- Replacing the cover on top of the engine
- Replacing the oil pump and front crankshaft seal
- Replacing the timing belt
- Turbocharged engine assembly with the transmission, installing
- VVT-unit, replacing/adjusting
- Ignition, Engine Control (B4204T4; 2003-2004)
- Engine Mechanical (B4204T4; 2003-2004)
- Camshaft seals, replacing
- Crankshaft seal rear, replacing
- Cylinder head/gasket, replacing
- Engine replacement, transferring components
- Removing turbocharged engines with the transmission
- Replace the engine mountings
- Replacing the cover on top of the engine
- Replacing the oil pump and front crankshaft seal
- Replacing the timing belt
- Turbocharged engine assembly with the transmission, installing
- VVT-unit, replacing/adjusting
- Oil Pan (B4204T2 CVVT; 2000)
- Oil Pan (B4204T3 (Ca) (Us); 2001-2003)
- Oil Pan (B4204T4; 2003-2004)
- Replacing Dual Mass Flywheel (B4204T2 CVVT; 2000)
- Replacing the dual mass flywheel
- Notes
- Preparatory work
- Removing the flywheel
- Installing the flywheel
- Reinstall the transmission
- Test driving and checking
- Crankshaft seal rear, replacing
- Checking/replacing the clutch driven plate and self-adjusting clutch
- Notes
- Removal
- Aligning the counterhold for automatic clutch adjustment
- Installing the compression tool
- Relieve the load from the diaphragm spring
- Checking the clutch
- Check the pressure plate for out-of-true
- Checking the clutch driven plate
- Check that there are no cracks or large scratches on the flywheel
- Installation
- Clutch driven plate, installing
- Install the tools on the clutch
- Installing the clutch
- Remove the tools
- Replacing the dual mass flywheel
- Replacing Dual Mass Flywheel (B4204T3 (Ca) (Us); 2001-2003)
- Replacing Dual Mass Flywheel (B4204T4; 2003-2004)
- Replacing Piston Cooling Valves (B4204T2 CVVT; 2000)
- Replacing Piston Cooling Valves (B4204T3 (Ca) (Us); 2001-2003)
- Replacing Piston Cooling Valves (B4204T4; 2003-2004)