Removal And Installation: Right

REMOVAL 

1. Remove the right timing chain and sprocket. Refer to CHAIN AND SPROCKETS, TIMING, REMOVAL AND INSTALLATION .

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2. Remove the bolts (1a) and the turbocharger heat shield (1b).

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3. Remove the engine oil dipstick (1).
4. Remove the bolt (2a) and the engine oil dipstick pipe (2b) from the block, complete with O-rings (2c).

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5. Remove the bolt (1a) securing the ground wire (1b).
6. Disconnect the fuel injector No. 3 wire harness connector (2).

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7. Disconnect the knock sensor wire harness connector (1).

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8. Remove the bolts (1a) and the bracket (1b) complete with low pressure fuel pipe aside.

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9. Remove the bolt (1a) and disengage the wiring retaining collar (1b).

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10. Remove the connector (1a) securing the low pressure fuel tube (1b).

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11. Disconnect the fuel pump pressure regulator wire harness connector (1).
12. Disconnect the air temperature and pressure sensor wire harness connector (2).

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13. Remove the bolt (1a) and the air temperature and pressure sensor (1b) complete with O-ring (1c).

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14. Remove the bolt (1a) fixing the wiring retaining collar (1b).

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15. Disengage the wiring from the retaining clip (1a) and disconnect the throttle body wire harness connector (1b).

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16. Disconnect the right turbocharger lubrication deactivation circuit oil pressure sensor wire harness connector (1).
17. Disconnect the right turbocharger lubrication deactivation circuit solenoid valve wire harness connector (2).

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18. Disconnect the wastegate solenoid valve wire harness connector (1).
19. Disconnect the deactivation solenoid valve of cylinder 1 wire harness connector (2), intake side.

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20. Disconnect the ignition coil of cylinder 1 wire harness connector (1).
21. Disconnect the deactivation solenoid valve of cylinder 1 wire harness connector (2), exhaust side.

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22. Disconnect the deactivation solenoid valve of cylinders 2 - 3 wire harness connector (1), exhaust side.
23. Disconnect the right cylinder head tappets deactivation circuit engine oil pressure sensor wire harness connector (2).
24. Remove the bolt securing the wiring retaining collar (3).

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25. Disconnect the Camshaft Position (CMP) sensor wire harness connector (1), exhaust side.
26. Disconnect the deactivation solenoid valve of cylinders 2 - 3 wire harness connector (2), intake side.

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27. Disconnect the CMP sensor wire harness connector (1), intake side.
28. Disconnect the ignition coils of cylinders 2 - 3 wire harness connector (2).

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29. Disconnect the Variable Valve Timing (VVT) solenoid wire harness connectors (1).

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30. Disconnect the fuel pressure sensor wire harness connector (1).

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31. Remove the bolts (1a) and the intake manifold (1b).
32. Remove the gasket.

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33. Disconnect the fuel injectors 1 - 2 wire harness connector (1).

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    NOTE:

    The high pressure fuel pipe must always be replaced every time it is removed.

34. Remove the bolt (1a), the connectors (1b), and the high pressure fuel pipe (1c).

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35. Remove the bolts (1a) securing the pressure pump (1b) wiring retaining bracket.

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    NOTE:

    Handle the pressure pump with care because accidental knocks could compromise its operation.

36. Remove the bolts (1a) and the pressure pump (1b) complete with wiring retaining bracket and O-ring (1c).

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37. Remove the roller tappet (1).

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38. Remove the bolts (1a) and the ignition coils (1b).

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39. Loosen the clamp (1a) and disconnect the air vacuum hose (1b).

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40. Remove the air vacuum hose middle retaining bracket (1b) bolt (1a).

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41. Loosen the clamp (1a) and disconnect the turbocharger actuator (1b) air vacuum hose.
42. Remove the air vacuum hose retaining bracket bolt (2).

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43. Remove the bolts (1a) and the wastegate solenoid valve (1b) complete with pipes.

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44. Remove the bolts (1a) and disengage the flange (1b) securing the deactivation solenoid valve of cylinders 2 - 3, intake side.

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45. Remove the bolts (1a) and disengage the flange (1b) securing the deactivation solenoid valve of cylinders 2 - 3, exhaust side.

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46. Remove the bolts (1a) and the flange (1b) securing the deactivation solenoid valve of cylinder 1, exhaust side.
47. Remove the bolts (2a) and the flange (2b) securing the deactivation solenoid valve of cylinder 1, intake side.

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48. Using a suitable tool (1a), remove the deactivation solenoid valve of cylinders 2 - 3 (1b), intake side, complete with O-rings (1c).
49. Proceed in the same way to remove the remaining deactivation solenoid valves.

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50. Remove the bolt (1a) and the VVT solenoids (1b) complete with O-rings (1c).

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51. Remove the left-handed bolt (1a) and the intake side variator (1b) complete with washer (1c).

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52. Remove the (special tool #2024000090, Guide Pins, Camshaft) (1).

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53. Remove the bolts (1a) and disconnect the engine oil vapor recovery pipe (1b) complete with O-ring.

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54. Remove the bolts (1a) and the right cylinder head tappets deactivation circuit oil pump (1b), complete with shaft (1c), gasket (1d) and centering dowels (1e).

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55. Remove the bolt (1a) and disconnect oil delivery pipe to the turbocharger (1b), complete with O-ring (1c).

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56. Remove the right turbocharger lubrication deactivation circuit engine oil pressure sensor (1a) and sealing washer (1b).

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57. Remove the right cylinder head tappets deactivation circuit engine oil pressure sensor (1a) and sealing washer (1b).

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58. Remove the bolt (1a) and CMP sensors (1b) complete with O-rings (1c).

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59. Remove the bolts (1a) and the engine oil filler (1b) complete with O-ring (1c).

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60. Remove the bolts (1a) and the cylinder head cover (1b).

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61. Remove the cylinder head cover gasket (1).
62. Remove the engine oil pipe middle seal (2).

INSTALLATION 

1. Install NEW  gasket, inserting them in the special grooves in the cylinder head.
2. Install the NEW  engine oil duct O-rings, inserting them in the grooves provided in the cylinder head.

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3. Apply a 2 +/- 0.5 mm bead of Dow Corning® sealant in the places shown in illustration (1).
   Fig 1: Cylinder Head Cover Bolts Tightening Sequence

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4. Install the cylinder head cover and tighten the bolts finger tight.
5. Using the tightening sequence shown in illustration, tighten the bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

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6. Using a NEW  O-ring, install the engine oil filler (1a) and tighten the bolts (1b) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

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7. Using a NEW  O-ring, install the Camshaft Position (CMP) sensors (1a), and tighten the screws (1b) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

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8. Using a NEW  gasket, install the right cylinder head tappets deactivation circuit engine oil pressure sensor and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

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9. Using a NEW  gasket, install the right turbocharger lubrication deactivation circuit engine oil pressure sensor and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

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10. Using a NEW  O-ring, install the oil pipe to the turbocharger (1a) and tighten the bolt (1b) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

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11. Using a NEW  gasket and centering dowels, Install the right cylinder head (1a) tappets deactivation circuit oil pump and tighten the bolts (1b) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

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    NOTE:

    Lubricate the screw (1b) with engine oil before tightening it.

12. Using a NEW  washer and NEW  left-handed bolt (1b), install the intake side variator (1a) and tighten the NEW  bolt (1b) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
13. Using a NEW  O-ring, install the engine oil vapor recovery tube and securely tighten the bolts.

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14. Using a NEW  O-ring, install the Variable Valve Timing (VVT) solenoids (1a) and tighten the bolts (1b) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
15. Using a NEW  O-ring, install the intake side deactivation solenoid valve of cylinders 2 - 3.
16. Install the deactivation solenoid valve flange and securely tighten the bolts.
17. Proceed in the same way to install the remaining deactivation solenoid valves.
18. Install the wastegate solenoid valve complete with tubes, and securely tighten the bolts.
19. Connect the air vacuum hoses and tighten the bands.
20. Securely tighten the air vacuum tube bolts.

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21. Install the ignition coils (1a) and tighten the bolts (1b) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
22. Install the roller tappet.

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23. Using a NEW  O-ring, install the pressure pump (1a) complete with the wiring retaining bracket and tighten the bolts (1b) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

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24. Install the NEW  high pressure fuel pipe (1a) and tighten the connector (1b) and the bolt of the middle bracket (1c) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
25. Connect the fuel injectors 1 - 2 wire harness connector.
    Fig 2: Intake Manifold Bolts Tightening Sequence

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26. Using a NEW  gasket, install the intake manifold and tighten the bolts finger tight.
27. Using the tightening sequence shown in illustration, tighten the bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
28. Connect the fuel pressure sensor wire harness connector.
29. Connect the VVT solenoids wire harness connectors.
30. Connect the wire harness connector for cylinders 2 - 3 ignition coils.
31. Connect the CMP sensor wire harness connector, intake side.
32. Connect the deactivation solenoid valve of cylinders 2 - 3 wire harness connector, intake side.
33. Connect the CMP sensor wire harness connector, exhaust side.
34. Tighten the bolt securing the wiring retaining collar.
35. Connect the right cylinder head tappets deactivation circuit engine oil pressure sensor wire harness connector.
36. Connect the deactivation solenoid valve of cylinders 2 - 3 wire harness connector, exhaust side.
37. Connect the deactivation solenoid valve of cylinder 1 wire harness connector, exhaust side.
38. Connect the ignition coil for cylinder 1 wire harness connector.
39. Connect the deactivation solenoid valve of cylinder 1 wire harness connector, intake side.
40. Connect the wastegate solenoid valve wire harness connector.
41. Connect the right turbocharger lubrication deactivation circuit solenoid valve wire harness connector.
42. Connect the right turbocharger lubrication deactivation circuit oil pressure sensor wire harness connector.
43. Connect the throttle body wire harness connector and engage the wiring with the retaining clips.
44. Tighten the wiring retaining collar bolt.
45. Using a NEW  O-ring, install the air temperature and pressure sensor and securely tighten the bolt.
46. Connect the air temperature and pressure sensor wire harness connector.
47. Connect the fuel pump pressure regulator wire harness connector.

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48. Install the low pressure fuel tube (1a) and tighten the connector (1b) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
49. Engage the retaining collar wiring and securely tighten the bolt.
50. Install the bracket complete with low pressure fuel tube and securely tighten the bolts.
51. Connect the knock sensor wire harness connector.
52. Connect the fuel injector 3 wire harness connector.
53. Install the ground wire and securely tighten the bolt.
54. Using a NEW  O-rings, install the engine oil dipstick tube and securely tighten the bolts.
55. Install the engine oil dipstick.
56. Install the turbocharger heat shield and securely tighten the bolts.
57. Install the right timing chain and sprocket. Refer to CHAIN AND SPROCKETS, TIMING, REMOVAL AND INSTALLATION .