Repair of gasoline engine FAM II 2.4D Chevrolet Captiva 1

Table of special tools
KM-653 Valve spring compressor adapter KM-135 Oil pressure gauge adapter KM-805 Valve guide knob J-36972 Crankshaft rear oil seal mounting tool KM-571-B...

Air cleaner assembly
Removal procedure 1. Disconnect the negative battery cable. 2. Disconnect the intake air temperature sensor connector (IAT). 3. Loosen the clamp and disconnect...

Air filter element
Removal procedure 1. Loosen the clamp and disconnect the air filter outlet hose from the air filter housing. 2. Loosen the air filter element cover screws. 3....

Cylinder head cover
Removal procedure 1. Disconnect the negative battery cable. 2. Remove the bolts and nuts from the decorative engine cover. 3. Remove the engine cover screw. 4....

Accessory drive belt
Removal procedure 1. Raise and secure the vehicle. 2. Remove the right front wheel. Follow Section 2E, Tires and wheels. 3. Remove the front engine cover from...

Cylinder head and gasket
Necessary equipment KM-470-B Angle Torque Indicator DW 110–060 Engine clamp Removal procedure 1. Remove the fuel pump fuse. 2. Start the engine. After stopping...

Camshafts
Removal procedure 1. Remove the engine cover screw. 2. Remove the timing belt. follow the paragraph «The drive belt of the gas distribution mechanism» in this...

Checking and adjusting the tension of the timing belt
Adjustment Procedure 1. Disconnect the negative battery cable. 2. Disconnect the intake air temperature sensor connector (IAT). 3. Remove the air filter...

The drive belt of the gas distribution mechanism
Removal procedure 1. Disconnect the negative battery cable. 2. Disconnect the intake air temperature sensor connector (IAT). 3. Remove the engine cover screw....

Oil pan
Removal procedure 1. Disconnect the negative battery cable. 2. Remove the bottom engine cover. 3. Remove the oil filler cap. 4. Remove the oil pan drain plug...

Oil pump
Removal procedure 1. Disconnect the negative battery cable. 2. Remove the timing belt. follow the paragraph «The drive belt of the gas distribution mechanism»...

Engine mount (right side)
Necessary equipment DW 110–060 Engine clamp Removal procedure Attention! Raise the engine just enough to take the load off the engine mount, otherwise damage...

Gearbox suspension assembly with final drive (left side)
Necessary equipment DW 110–060 Engine clamp Removal procedure 1. Remove the battery and battery tray. See section 1E2, engine electrical equipment - FAM II...

Knot of a forward suspension bracket of a transmission with the main transfer assy
Necessary equipment DW 110–060 Engine clamp Removal procedure Attention! Raise the engine just enough to take the load off the transaxle front suspension...

Knot of a back suspension bracket of a transmission with the main transfer assy
Necessary equipment DW 110–060 Engine clamp Removal procedure Attention! Raise the engine just enough to take the load off the transaxle rear mount assembly,...

Intake manifold
Removal procedure 1. Disconnect the negative battery cable. 2. Drain the engine coolant. See Section 1D2, Engine Cooling System - FAM II 2.4D. 3. Disconnect...

An exhaust manifold
Removal procedure 1. Disconnect the negative battery cable. 2. Disconnect the front heated oxygen sensor connector. 3. Loosen the retaining bolts of the...

Camshaft Gears
Removal procedure 1. Disconnect the negative battery cable. 2. Remove the engine cover screw. 3. Disconnect the ignition wires from the spark plugs. 4....

Rear cover of the gas distribution mechanism drive belt
Necessary equipment KM-470-B Angle Torque Indicator Removal procedure 1. Disconnect the negative battery cable. 2. Remove the timing belt. follow the paragraph...

Removal and installation of the engine
Necessary equipment EN-48243 Engine Removal/Installation Rack Assembly EN-48244 Rack bracket for engine removal/installation assembly Removal procedure 1....

Knot of the balance weight of a cranked shaft assy
Removal procedure 1. Remove the oil pan. follow the paragraph «oil pan» in this section. 2. Dismantle the oil suction tube with O-ring. 3. Remove the oil pan....

Pistons and connecting rods
Necessary equipment J-8037 Universal Piston Ring Compressor J-8087 Cylinder Bore Gauge KM-427 Piston ring maintenance kit KM-470-B Angle Torque Indicator...

Cylinder head and valve train parts
Necessary equipment KM-571-B Meter KM-340-0 Cutting tool set KM-340-7 Guide barb KM–340–13 Cutting tools KM–340–26 Cutting tools KM-348 Valve Spring Compressor...

Crankshaft — disassembly and assembly
Necessary equipment DW100-030 Engine overhaul stand KM-470-B Angle Torque Indicator J–36972 or KM–635 Crankshaft rear oil seal Note: Be especially careful not...

Main and connecting rod bearings — calibrated plastic wire
Necessary equipment KM-470-B Angle Torque Indicator Inspection Procedure - Crankshaft 1. Lubricate the main bearings with engine oil. 2. Install the upper main...