Engine dismantling, examination, renovation and reassembly - general information

Dismantling
1 Refer to Chapter 2, Part A, Section 18, paragraphs 1 to 8 inclusive.

2 A suitable selection of splined and Torx sockets will be required to remove many of the bolts when dismantling the engine.

3 Before dismantling the main engine components, the following externallymounted ancillary components can be removed, with reference to the relevant Chapters of this Manual and the relevant Sections of this Chapter, where applicable.

Inlet manifold (and carburettor, if applicable) Exhaust manifold
Alternator.

Coolant pump, and thermostat Alternator/coolant pump drivebelt tensioner Distributor cap, HT leads and spark plugs Oil pressure warning lamp switch Crankshaft speed/position sensor Oil filter
Dipstick
Engine mounting brackets (if not already done) Crankcase ventilation pipe and hoses Clutch
Alternator mounting bracket.

Air conditioning compressor mounting bracket (where applicable).

Engine lifting brackets.

Examination and renovation 4 Refer to Chapter 2, Part A, Section 18, but note that the connecting rod bolts should be renewed on reassembly, and when renewing the cylinder head bolts, the latest type bolts with hexagonal heads should always be used.

Reassembly
5 Proceed as described in Chapter 2, Part A, Section 18, noting the following: 6 If they have been removed, new cylinder head bolts (both M11 and M8, of the latest type with hexagonal heads), flywheel bolts, and connecting rod bolts must be used.

    See also:

    Handbrake lever - removal and refitting
    Removal 1 Chock the front wheels, raise and support the vehicle at the rear using stands (see “Jacking and Vehicle Support”) then release the handbrake. 2 Working underneath, extract the spring c ...

    Fuel injectors and injector delivery pipes - removal and refitting
    Note: Refer to the precautions at the end of Section 1 before proceeding. It is important to note that each injection supply pipe connection in the distributor head has a screw adjacent to it. The ...

    Engine/manual gearbox assembly - reconnection and refitting
    1 Reverse the procedure described in paragraphs 1 to 33 of Section 7, noting the following points. 2 Before attempting to reconnect the engine to the gearbox, check that the clutch friction disc ...