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:

    Distributor cap and rotor arm (OHC models) - removal and refitting
    SOHC models 1 Disconnect the battery negative lead. 2 Where applicable, unclip the screening can from the top of the distributor and disconnect the earth strap (see illustration). 13.2 Unclippi ...

    Radiator fan thermal switch - testing, removal and refitting
    Testing 1 The thermal switch is located on the side of the thermostat housing on early OHV engine models and in the thermostat housing cover on later OHV versions. On all CVH engines, the switch ...

    Tailgate wiper motor - removal and refitting
    Removal 1 Disconnect the battery and remove the wiper arm/blade assembly. 2 Remove the pivot shaft nut, spacer and outer seals. 3 Open the tailgate and remove the trim panel (refer to Chapter 11 ...