Engine Components - Removal, Replacement And Installation

• Ignition, Engine Control (B4204T2 CVVT; 2000)
  • Ignition coil(s), replacement
    • Notes
    • Removing the ignition coil(s)
    • Installing the rubber and spring from the ignition coil
    • Installing the ignition coil(s)
  • Replacing spark plugs
    • Notes
    • Removing
    • Installing
  • Replacing the idle air control (IAC) valve
    • Removing
    • Installing
  • Replacing the mass air flow (MAF) sensor
    • Removing
    • Installing
  • Replacing the turbocharger (TC) control valve
    • Removing
    • Installing
  • Replacing the variable valve timing (VVT) control valve
    • Preparations
    • Remove the valve housing assembly
    • Install the valve housing assembly
  • Replacing the variable valve timing solenoid
    • Remove the cover from the timing gear
    • Removing the variable valve timing system
    • Install the variable valve timing system
    • Install the cover on the timing gear
• 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
    • Notes
    • Removing the flywheel and carrier plate
    • Removing the seal
    • Installing the sealing ring
    • Installing flywheel and carrier plate
    • Installing the gearbox
    • Checking the engine:
    • Gearbox, fitting
  • 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
    • Notes
    • Conditions
    • Replacing the right-hand engine mounting
      • Installing the lifting beam and lifting hook
      • Removing the right-hand engine mounting
      • Installing the right engine mounting
      • Finishing
    • Replacing the left-hand engine mounting
      • Removing the left-hand engine mounting
      • Installing the left-hand engine mounting
    • Replacing the front engine mounting
      • Removing the front engine mounting
      • Installing the front engine mounting
    • Replacing the rear engine mounting
      • Removing the rear engine mounting
      • Installing the rear engine mounting
    • Replacing the air cleaner (ACL)
      • Notes
      • Preparations
      • Removing the air cleaner (ACL) housing
      • Installing the air cleaner (ACL) housing
      • Installing the battery
  • Replacing the cover on top of the engine
    • Overview
    • Notes
    • Removing the cover on top of the engine
    • Installing the cover on top of the engine
  • Replacing the oil pump and front crankshaft seal
    • Notes
    • Removing the timing belt
    • Removing the vibration damper
    • Removing the crankshaft timing gear pulley
    • When only replacing the front crankshaft seal
    • Removing the oil pump
    • Installing the oil pump
    • Installing the vibration damper
    • Installing the timing belt
  • 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
    • Overview
    • Notes
    • Preparations
    • Removing the variable valve timing (VVT) unit
    • Removing the timing gear pulley
    • Secure the crankshaft position
    • Installing VVT-unit
    • Installing the timing gear pulley
    • Installing the timing belt
    • VVT unit/timing gear pulley, tightening
    • Check
    • Finishing
  • Replacing camshaft seal (retaining ring) front side
    • Notes
    • Remove
      • Remove camshaft seal at VVT unit side
      • Remove camshaft retaining ring
    • Install
      • Install camshaft retaining ring
  • Replacing engine mounting bolsters
    • Notes
    • Prerequisites
    • Replace engine mounting bolster at distributor side
    • Replacing engine mounting bolster at transmission side
    • Replace front engine mounting bolster
    • Replace rear engine mounting bolster
  • Replacing flange plate
    • Notes
    • Remove flange plate
    • Install flange plate
  • Replacing rearmost crankshaft retaining ring
    • Notes
    • Removing flange plate
    • Replacing retaining ring
    • Installing flange plate
  • 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
• Ignition, Engine Control (B4204T3 (Ca) (Us); 2001-2003)
  • Ignition coil(s), replacement
  • Replacing spark plugs
  • Replacing the idle air control (IAC) valve
  • Replacing the mass air flow (MAF) sensor
  • Replacing the turbocharger (TC) control valve
  • Replacing the variable valve timing (VVT) control valve
  • Replacing the variable valve timing solenoid
• 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)
  • Ignition coil(s), replacement
  • Replacing spark plugs
  • Replacing the idle air control (IAC) valve
  • Replacing the mass air flow (MAF) sensor
  • Replacing the turbocharger (TC) control valve
  • Replacing the variable valve timing (VVT) control valve
  • Replacing the variable valve timing solenoid
• 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)
  • Replace the oil pan
    • Notes
    • Preparations
    • Removing the front-rear member
    • Removing the oil cooler
    • Removing the oil pan
    • Cleaning
    • Installing the oil pan
    • Installing the front-rear member
    • Replacing the oil and oil filter
• Oil Pan (B4204T3 (Ca) (Us); 2001-2003)
  • Replace the oil pan
• Oil Pan (B4204T4; 2003-2004)
  • Replace the oil pan
• 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 Dual Mass Flywheel (B4204T3 (Ca) (Us); 2001-2003)
  • Replacing the dual mass flywheel
• Replacing Dual Mass Flywheel (B4204T4; 2003-2004)
  • Replacing the dual mass flywheel
• Replacing Piston Cooling Valves (B4204T2 CVVT; 2000)
  • Replacing piston cooling valves
    • Removing the timing belt and mechanical timing belt tensioner
    • Removing components
    • Installing components
    • Installing the timing belt
• Replacing Piston Cooling Valves (B4204T3 (Ca) (Us); 2001-2003)
  • Replacing piston cooling valves
• Replacing Piston Cooling Valves (B4204T4; 2003-2004)
  • Replacing piston cooling valves