Engines 1.9 l
Removing the Top Cover
1. Disconnect the ground wire from the battery (see «Disconnecting the battery»).
2. Release the clip in the center of the engine cover and remove the screw on the right. Remove the engine cover (pic. 4.1, a-c).
3. Fully apply the parking brake. Raise the front of the vehicle and securely jack stands under it (see «Lifting and placing the car on supports»). Remove the right front wheel.
4. To gain access to the right end of the engine, remove the plastic wheel arch locker. The locker is fixed with various screws and clamps. Release all fasteners and remove the locker from under the front fender. If necessary, release the coolant hoses under the fender to facilitate further access.
5. Disconnect the fuel supply and return fuel hose quick couplings at the connections near the fuel pump using a small screwdriver to release the locking clip. Seal open ports to prevent dirt from entering by using small plastic bags or «fingers», cut from clean rubber gloves.
6. Release the two hoses from the clips on the top cover of the timing belt and slide them to the side (pic. 6.6).
Pic. 6.6. Release the fuel lines from the clips on the top cover of the timing belt (engines 1.9 l)
7. Connect the engine jack to the two lifting brackets on the cylinder head. Raise the lifting device just enough to relieve the engine mounts.
8. For added stability, place a jack under the right side of the engine by placing a block of wood on top of the jack head. Raise the jack just enough to make contact with the oil pan.
9. Turn out three bolts of fastening of the top bracket of the right support of the engine/gearbox to the bottom bracket (on the engine). Loosen the single nut securing the top bracket to the rubber mount. Remove the top bracket from the rubber support and lower the bracket (on the engine).
10. Remove the two nuts and pinch bolts securing the engine/gearbox rear mount tie to the support bracket on the subframe and on the rear of the cylinder block. Release the tie and remove it from the support brackets.
11. After removing the two engine mounts, alternatively raise and lower the hoist and jack under the engine as far as necessary to gain access to the timing belt cover bolts.
12. Turn out a bolt of fastening of the top cover to a cover of a head of cylinders (pic. 6.12)
Pic. 6.12. Arrangement of bolts of fastening of a cover of a timing belt (marked with arrows) (engines 1.6 l)
13. Remove the two bolts in the connection between the top cover and bottom cover, one in the center just below the motor support bracket and one on the outer edge. Keep in mind that the bolt on the outer edge also serves to mount the coolant pump. To prevent coolant leakage, after removing the cover, install the bolt with a 5.0 mm spacer on it and tighten it securely.
14. Remove the remaining bolt just above the stoked high pressure pump sprocket.
15. Release the mounting tabs, release the top section from behind the intermediate cover and remove the top cover.
Removing the intermediate cover
16. Remove the top cover as described above.
17. Remove the remaining bolt at the base of the cover just below the motor support bracket.
18. Release the mounting tabs and remove the intermediate cover.
Removing the bottom cover
19. Remove the top and intermediate covers as described above.
20. Remove the crankshaft pulley as described in paragraph 5.
21. Remove the two remaining bolts on the edge of the cover, one on each side of the crankshaft pulley mounting location.
22. Remove the cover from the front of the engine.
Installation
23. Install all covers in the reverse order of removal, correctly fix each section of the cover and securely tighten the cover bolts. Connect all disturbed hoses and fix them with appropriate clamps. Tighten all nuts/bolts to specified torque (if given). Finally, fill and bleed the fuel system as described chapter 4B.
Engines 2.0 l
Attention! Before starting the procedure, read the precautions contained in paragraph 1.
Removing the Top Cover
24. Disconnect the ground wire from the battery (see «Disconnecting the battery»).
25. Rotate the four plastic tabs 90°and remove the engine cover (pic. 6.25, a, b).
Figure 6.25, a. Turn each latch a quarter of a turn to release it...
Pic. 6.25 b....and then remove the engine cover (engines 2.0 l)
26. Fully apply the parking brake. Raise the front of the vehicle and securely jack stands under it (see «Lifting and placing the car on supports»). Remove the right front wheel.
27. To gain access to the right end of the engine, remove the plastic wheel arch locker. The locker is fixed with various screws and clamps. Release all fasteners and remove the locker from under the front fender. If necessary, release the coolant hoses under the fender to facilitate further access.
28. Disconnect the fuel supply and return fuel hose quick couplers at the connections near the fuel pump using a small screwdriver to release the locking clip (6.28). Seal open ports to prevent dirt from entering using small plastic bags or «fingers», cut from clean rubber gloves.
Pic. 6.28. Disconnect the quick connect fuel supply and return hoses (engines 2.6 l)
29. Release the two hoses from the clips on the top cover of the timing belt and slide them to the side (pic. 6.29).
Pic. 6.29. Release the two hoses from the clips on the top cover of the timing belt (engines 2.0 l)
30. On early engines, remove the EGR solenoid valve support bracket bolt and slide the valve to the side.
31. Turn out two bolts of fastening of an intensifying arm of the right support to a body and remove an arm together with the gauge of position of a pedal of an accelerator (on later engines) (pic. 6.31).
Pic. 6.31. Remove two screws (marked with arrows) and remove the booster bracket and pedal position sensor (late 2.0L engines)
32. Attach an engine jack to the two lifting brackets on the cylinder head. Raise the lifting device just enough to relieve the engine mounts. For added stability, place a jack under the right side of the engine by resting a block of wood on top of the jack head. Raise the jack just enough to make contact with the oil pan.
33. Turn out three bolts of fastening of the top bracket of the right support of the engine/gearbox to the bottom bracket (on the engine).
34. Remove the domed buffer nut and then remove the single nut securing the top bracket to the rubber mount. Remove the top bracket from the rubber support and bottom bracket (on the engine).
35. Turn away two nuts and remove coupling bolts of fastening of a coupler of a back support of the engine/transmission to a basic arm on a stretcher and on a back part of the block of cylinders. Release the tie and remove it from the support brackets.
36. After removing the two engine mounts, alternatively raise and lower the hoist and jack under the engine as far as necessary to gain access to the timing belt cover bolts.
37. Turn out a bolt of fastening of the top cover to a cover of a head of cylinders (pic. 6.37).
Pic. 6.37. Arrangement of bolts of fastening of a cover of a timing belt (marked with arrows) (engines 2.0 l)
38. Turn out the top bolt on the edge of the cover, closest to the bulkhead of the engine compartment.
39. Remove the bottom bolt on the cover on the bulkhead side, at the junction between the top and bottom covers. Keep in mind that this bolt also holds the coolant pump. To prevent coolant leakage, after removing the top cover, install a bolt with a 17.0 mm spacer attached and tighten it securely.
40. Remove the remaining bolt in the center of the cover, just above the motor support bracket.
41. Unhook the top cover from the intermediate cover and remove the top cover.
Removing the intermediate cover
42. Remove the top cover as described above.
43. Turn out the top bolt on the top edge of an intermediate cover.
44. Remove the two remaining bolts in the connection between the intermediate cover and the bottom cover, and then remove the intermediate cover.
Removing the bottom cover
45. Remove the crankshaft pulley as described in paragraph 5.
46. Remove the top and intermediate covers as described above.
47. Remove the two remaining bolts on the edge of the cover, one on each side of the crankshaft pulley.
48. Remove the cover from the front of the engine and remove it.
Installation
49. Installation of all covers is carried out in the reverse order of removal. Properly fix each section of the cover and tighten the cover bolts securely. Connect all disturbed hoses and fix them with appropriate clamps. Tighten all nuts/bolts to specified torque (if given). Finally, fill and bleed the fuel system as described in chapter 4B.