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:

    Fuel evaporative emission control system components (Central Fuel Injection/CFI engines) - removal and refitting
    Carbon canister Removal 1 The carbon canister is located behind the bumper, under the front right-hand wheelarch (see illustration). 5.1 Carbon canister location (wheelarch liner removed) - CFI ...

    Crankcase ventilation system check (Every 12 000 miles (20 000 km) or 12 months)
    1 Inspect the crankcase ventilation system for blockage or damage. A blocked hose can cause a build-up of crankcase pressure, which in turn can cause oil leaks (see illustration). 35.1 Loosenin ...

    Tailgate - removal and refitting
    Removal 1 Remove the trim panel (Section 32). 2 Disconnect the wiring from the heated rear window element, radio aerial, wiper motor tailgate speakers and tailgate lock motor as applicable (see i ...