Removal

1. Disconnect the negative battery lead.
2. Raise the car and remove the center air shield. Position a collecting tray under the engine and open the radiator drain plug. Lower the car.
3. Lift the power steering servo oil reservoir and free the lead from the torque arm engine mounting.
4. Remove the torque arm.
5. Remove the servo line clamp from the torque arm engine mounting and remove the engine mounting.
6. Slightly slacken the pulley bolts. Release the load from the belt tensioner by turning the belt tensioner pulley forwards in the car using a 15 mm wrench. Remove the belt from the coolant pump pulley and carefully release the belt tensioner.
7. Detach the other hoses from the expansion tank and remove the coolant pump pulley.
8. Remove the upper part of the generator air intake and remove the belt tensioner.
9. Detach the power steering servo pump and move it aside.
10. Remove the timing cover.
11. Remove the crankshaft pulley (remove the six bolts. not the center bolt)





12. Zero the engine. The marks on the camshaft sprockets and the timing cover should align as should the markings on the crankshaft. Insert locking tools KM-800-1 and KM-800-2 for the camshaft sprockets on the cylinder heads and locking tool KM-800-10 for the crankshaft.
13. Before the toothed belt is removed, mark the belt's direction of rotation. To facilitate installing, the belt can be marked at both the camshaft marking and the crankshaft marking.
14. Release the belt from tension and remove the toothed belt. Undo the adjuster pulley bolts.
15. Turn the crankshaft back to 60° BTDC.
16. Remove the bracket holding the upper adjuster pulley and the tensioner pulley.





17. Remove the coolant pump.

NOTE: There is quite a lot of coolant left in the engine. Always have a collecting tray under the engine when working on the cooling system.

18. Lock the camshaft sprockets with locking tools KM-800-1 and KM-800-2 and remove the camshaft sprockets. Remove the rear timing cover.
19. Raise the car and detach the front exhaust pipe from both exhaust manifolds.
20. Remove the protective plate.
21. Install holder 83 95 063, or equivalent and remove the crankshaft pulley.





22. Remove the alternator.
23. Remove the A/C compressor and hang it up.
24. Drain the engine oil.
25. Remove the oil pan and oil strainer.
26. Disconnect the cable for the oil pressure switch.
27. Lower the car place a stand and wood block under the front edge of the engine block.
28. Remove the A/C compressor bracket.





29. Remove the oil pump housing.
30. Remove the cover and extract the two impellers.
31. If necessary, check the oil pressure release valve and the oil pressure control valve. Torque the oil pressure release valve to 28 Nm (21 ft. lbs.) with a copper gasket or 20 Nm (15 ft. lbs.) with an aluminum gasket.