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| The engine must be no more than warm to touch. |
WARNING | When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions: |
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| Route all types of line (e.g. for fuel, hydraulics, activated charcoal filter system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original positions. |
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| Ensure that there is sufficient clearance to all moving or hot components. |
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Note | Before carrying out further work, disconnect battery earth strap. First check whether a coded radio is fitted. Obtain radio code first if necessary. |
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| With the ignition switched off, disconnect battery earth strap. |
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| All cable ties which are opened or cut open when engine is removed must be replaced in the same position when engine is installed. |
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| Remove upper part of intake manifold → Chapter. |
Note | Seal intake ports in the lower part of intake manifold using a clean cloth. |
WARNING | Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection. |
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| Pull the fuel supply line (white mark) off the fuel rail and place the wiring harness down forwards. |
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| Seal lines so that fuel system is not contaminated by dirt. |
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| Remove the connections with coolant hoses. |
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| Remove secondary air pump intake and pressure lines. |
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| Remove bracket of pressure line. |
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| Unbolt secondary air pump motor -V101- and bracket and remove. |
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| Pull off the following connectors: |
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| For secondary air pump motor -V101- |
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| For injectors (unclip cable guide) |
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| For spark plugs (with assembly tool -T10029-) |
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| Unbolt front exhaust pipe with catalytic converter and manifold support. |
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| Remove poly V-belt tensioner. |
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| Remove toothed belt guard - upper part. |
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