PRE-RELEASE
Camshaft covers, removed engine
| Camshaft covers, removed engine |
| To remove |
| 1. |
Remove the power train from the car; see
Power train, to remove
and
Power train, to remove, 4WD
.
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| 2. |
Remove other equipment from the engine; see
Replacing the engine (power train on the subframe)
and
Replacing the engine (power train on the subframe), 4WD
|
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| 3. |
Fit
32 025 048 Holder
on the engine and place the engine on an engine stand.
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| 4. |
Unplug the bypass valve connector (A).
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| 5. |
Detach the vacuum hoses and the crankcase ventilation pipe from the turbocharger (B).
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| 6. |
Remove the front lifting eye (A).
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| 7. |
Remove both of the secondary air injection pump's pipes (B) and unplug the connector.
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| 8. |
Remove the engine breather pipe (A) from the intake manifold.
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| 9. |
Remove the corner bracket (B) from the intake manifold.
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| 10. |
Remove the holder and unplug the connector for the injectors' wiring harness (C).
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| 11. |
Detach the brake vacuum hose (A) from the intake manifold and the venturi valve.
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| 12. |
Remove the crankcase ventilation pipes (B) from the intake manifold.
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| 13. |
Remove the coolant port (B). Cut the cable tie(A).
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| 14. |
Unplug the connectors from the camshafts' position sensor and from the camshafts' solenoid valves (A) and unplug the fuel pressure sensor's connector (B).
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| 15. |
Release the hooks and lift up the wiring harness holder (C).
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| 16. |
Unplug the connectors (A) for ignition coils 2, 4 and 6 as well as the front ground connections (B) and remove the wiring harness clips (C).
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| 17. |
Lift up the heat shield and unplug the coolant temperature sensor's connector (D).
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| 18. |
Unplug the fuel pressure sensor connector (A).
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| 19. |
Remove the bolts (B) and carefully lift off both intake manifolds as one unit.
At the same time unplug the throttle body connector and remove the cable from the clip (C). Remove the gasket and cover the inlet duct. |
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| 20. |
Remove the secondary air system's valve (A) for cylinders 2-4-6.
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| 21. |
Detach the turbocharger diaphragm unit by removing the bolts (A) so that the unit can be moved slightly to the side.
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| 22. |
Remove the secondary air pipe (A).
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| 23. |
Unplug the connectors (A) for ignition coils 1, 3 and 5.
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| 24. |
Remove the rear cable duct (B) from the camshaft cover. Use a screwdriver to release the clips.
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| 25. |
Secure the wiring harness on the rear of the engine using a cable tie.
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| 26. |
Remove ignition coils 2, 4 and 6 (A).
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| 27. |
Remove the front camshaft cover (B).
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| 28. |
Remove the gasket and the seals for the spark plug holes (C).
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| 29. |
Remove ignition coils 1, 3 and 5 (A).
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| 30. |
Remove the rear camshaft cover (B).
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| 31. |
Remove the gasket and the seals for the spark plug holes (C).
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| To fit |
| 1. |
Fit the spark plug hole seals and the gasket of the rear camshaft cover. Use
J-5590 Drift
and
J-24254-A Fitting tool
.
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| 2. |
Apply a spot of
93 160 951 Flange sealant
on each mating face between the cylinder head and the timing cover as illustrated.
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| 3. |
Fit the rear camshaft cover (A).
Tightening torque 10 Nm (7 lbf ft) 
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| 4. |
Fit ignition coils (B) 1, 3 and 5.
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| 5. |
Remove the clips (A) from the camshaft cover and fit them in the grooves on the cable duct (B).
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| 6. |
Fit the cable duct on the camshaft cover.
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| 7. |
Fit the connectors to ignition coils 1, 3 and 5.
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| 8. |
Fit the spark plug hole seals and the gasket of the front camshaft cover. Use
J-5590 Drift
and sleeve
J-24254-A Fitting tool
.
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| 9. |
Add a spot of
93 160 951 Flange sealant
on each mating surface between the cylinder head and timing cover as illustrated. Fit the front camshaft cover.
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| 10. |
Fit the front camshaft cover (A).
Tightening torque 10 Nm (7 lbf ft) 
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| 11. |
Fit ignition coils (B) 2, 4 and 6. Do not tighten ignition coil 4 yet.
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| 12. |
Fit the secondary air pipe (A). Use a new seal.
Tightening torque 10 Nm (8 lbf ft)
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| 13. |
Fit the secondary air system's check valve. Use a new seal.
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| 14. |
Fit the turbocharger's diaphragm unit by fitting the bolts (A).
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| 15. |
Fit a new gasket and carefully fit both intake manifolds (A) as one unit. At the same time, plug in the throttle body connector and fit the wiring harness clips (B).
Tightening torque 23 Nm (17 lbf ft)
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| 16. |
Fit the wiring harness in its fixings (C).
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| 17. |
Fit the front ground connections (B) and plug in the connectors (A) to ignition coils 2, 4 and 6. Tighten ignition coil 4.
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| 18. |
Lift up the heat shield and plug in the coolant temperature sensor's connector (D).
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| 19. |
Plug in the connectors for the front and rear camshaft position sensors and the connectors for the front and rear camshaft solenoid valves.
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| 20. |
Fit the fuel pressure sensor connector.
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| 21. |
Fit the coolant port (B) using a new seal and O-ring.
Tightening torque 10 Nm (748 lbf ft)
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| 22. |
Fit a new cable tie (A).
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| 23. |
Fit the crankcase ventilation pipes (B) to the intake manifold.
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| 24. |
Fit the brake vacuum hose (A) to the intake manifold and the valve.
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| 25. |
Fit the corner bracket (B) to the intake manifold.
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| 26. |
Fit the engine breather pipe (A) to the intake manifold.
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| 27. |
Plug in the connector and fit the bracket for the injectors (C).
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| 28. |
Fit the font lifting eye (A).
Tightening torque: 65 Nm (48 lbf ft)
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| 29. |
Plug in the connector and fit both of the secondary air injection pump's pipes (B).
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| 30. |
Fit the crankcase ventilation pipe to the turbocharger and fit the vacuum hoses (B).
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| 31. |
Plug in the bypass valve connector (A).
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| 32. |
Remove the engine from the stand and remove the holder from the engine.
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| 33. |
Fit other equipment to the engine; see
Replacing the engine (power train on the subframe)
and
Replacing the engine (power train on the subframe), 4WD
|
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| 34. |
Fit the power train to the car; see
Power train, to fit
and
Power train, to fit, 4WD
.
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