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:

    Horn - removal and refitting
    Removal 1 The horn(s) are located in the left-hand front corner of the engine compartment. Before removing, disconnect the battery. 2 Disconnect the lead from the horn. 3 Unscrew the single bolt ...

    Speedometer cable - removal and refitting
    Removal 1 Disconnect the battery and remove the instrument panel as described in Section 9. 2 Disconnect the cable from the transmission and release it from its clips and grommet. 3 Withdraw the ...

    Fuses and relays - location and renewal
    Location 1 The main fuses and relays are located in a box in the engine compartment on the righthand side of the bulkhead. The circuits protected are identified by symbols on the underside of the ...