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:

    Alternator drivebelt check (Every 6000 miles or 6 months)
    1 A conventional vee drivebelt is used to drive both the alternators and water pump pulleys on OHV and HCS engines, and the alternator pulley only on CVH engines, power being transmitted via a pul ...

    Exhaust system - renewal
    1 The layout of the exhaust system varies considerably according to model and engine. All except the RS Turbo versions can be renewed in sections; coupling sleeves are supplied, enabling an old se ...

    Brake fluid pipes and hoses - removal and refitting
    Caution: Refer to the precautions in Section 1. Removal 1 To remove a flexible hose, always free it from any mounting bracket(s) first by prising out the U-shaped retaining clip, and then using ...