Removal (1.6L)
- Drain cooling system and remove upper radiator hose. Remove breather and purge hoses. Remove air cleaner assembly and fuel line. Remove vacuum hose at distributor and purge control valve. Label and disconnect spark plug wires. Remove distributor.
- Disconnect heater hose at intake manifold. Disconnect water hose between cylinder head and injection mixer water case. Disconnect coolant temperature sending unit wire. Disconnect front exhaust pipe at exhaust manifold flange.NOTE: It may be necessary to remove turbocharger from exhaust manifold before exhaust manifold can be removed.
- Remove turbocharger heat protector. Remove oxygen sensor from catalytic converter. Remove converter-to-turbocharger nuts. Disconnect oil return hose from oil pan. Remove oil pipe from turbocharger and oil filter bracket. Remove air intake pipe connecting bolt. Disconnect water pipes from turbocharger. Remove turbocharger mounting nuts and remove turbocharger assembly from exhaust manifold.
- Remove exhaust manifold. Remove intake manifold and injection mixer as an assembly. Remove timing belt upper front cover. Rotate crankshaft so that No. 1 piston is at TDC. Align camshaft sprocket timing marks. Mark timing belt with felt pen or chalk in alignment with timing mark on camshaft sprocket.
- Remove camshaft sprocket bolt and camshaft sprocket with timing belt attached. DO NOT turn crankshaft. Ensure belt is prevented from disengaging from crankshaft or oil pump sprockets.
- Remove 3 timing belt upper inner cover retaining bolts. Remove timing belt upper inner cover. Remove rocker cover. Loosen cylinder head bolts using Head Bolt Wrench (TW-10B), in reverse of tightening sequence. See Figure. Loosen head bolts in 2 or 3 steps to prevent cylinder head warpage. DO NOT slide cylinder head across dowel pins during removal.