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:
Oil filler cap cleaning - OHVand HCS engines (Every 6000 miles
or 6 months)
1 Simply pull the oil filler cap from the rocker
cover and, where applicable, disconnect the
hose(s) from the cap.
2 Inspect the filler cap, and if necessary clean
the cap using clean petrol to re ...
Bonnet release cable - removal and refitting
Removal
1 Working inside the vehicle, extract the three
screws and remove the steering column
shroud. Open the bonnet. If the cable is broken,
the release latch must be operated using a
suitably ...
Load apportioning valve P100 models) - removal and refitting
Caution: Refer to the
precautions in Section 1.
Removal
1 Chock the front wheels, jack up the rear of
the vehicle and support on axle stands (see
“Jacking and Vehicle Support”).
2 The load appor ...
