We dismantle the engine for a major overhaul. Conventionally, the engine has already been removed from the vehicle.
The engine mounts have been removed and the engine is installed on a stand or test bench.
We remove the ignition module and the knock sensor; to do this:
We withdraw the high-tension lead terminals from the coil terminals.
We unscrew the four coil mounting screws using a 5 mm Allen key.
We remove the ignition coil.
Using a 13 mm spanner, we unscrew the sensor mounting bolt and remove the knock sensor.
We remove the air conditioning compressor drive belt; to do this:
We slacken the two bolts securing the tensioner roller bracket with a 13 mm socket.
Using a 13 mm socket, we turn the adjusting bolt anticlockwise.
And we remove the belt from the roller and the compressor pulley.
When fitting the belt, it must be borne in mind that it is located closer to the inner edge of the compressor pulley.
We remove the auxiliary drive belt; to do this:
Using a 13 mm socket, we slacken the tightening of the three nuts securing the tensioner roller bracket.
The layout of the belts can be seen in the photo.
Using a 13 mm socket, we turn the adjusting bolt anticlockwise and slacken the belt.
We remove the belt from the tensioner roller.
We remove the alternator; to do this:
Using a 13 mm spanner, we unscrew the nut of the alternator lower mounting bolt.
We withdraw the bolt.
We unscrew the nut of the alternator upper mounting bolt.
Holding the alternator, we withdraw the bolt.
We remove the alternator.
We remove the alternator bracket; to do this: using a 13 mm spanner, we unscrew the bolt securing the plate to the bracket.
We unscrew the two bolts of the bracket lower mounting.
Using a 13 mm socket, we unscrew the bolt of the bracket upper mounting.
We remove the alternator bracket.
We extract the gasket between the bracket and the block.
We remove the power steering pump and the oil filter bracket; to do this:
With a screwdriver we hold the pulley from turning and successively slacken the three bolts securing the pump pulley.
We remove the pulley.
Using a 13 mm box spanner, we unscrew the bolt of the pump plate lower mounting.
We unscrew the bolt of the plate upper mounting.
Using a 13 mm spanner, we unscrew the bolt of the pump lower mounting to the oil filter bracket.
We unscrew the bolt of the pump upper mounting.
We remove the pump together with the plate.
Using a 13 mm socket, we unscrew the three bolts securing the oil filter bracket to the block.
We remove the bracket with the support roller.
We remove the sealing rings.
We remove the crankcase ventilation oil separator, the sump and the oil pump; to do this:
Using a 13 mm box spanner, we unscrew the cap nut securing the cover.
We remove the copper sealing washer.
We remove the oil separator cover.
We remove the cover gasket.
We screw two M8 nuts onto the oil separator stud, lock them against each other and unscrew the stud.
We withdraw the oil separator mounting stud.
With pliers we withdraw the oil separator from its seat in the cylinder block.
Using a 10 mm socket, we unscrew the nineteen bolts securing the sump to the cylinder block.
We remove the sump.
We extract the sump gasket.
Using a 13 mm socket, we unscrew the two bolts securing the oil pump to the block.
We withdraw the oil pump mounting bolts.
We remove the oil pump sealing gasket.
We remove the coolant pump; to do this:
Using a 13 mm socket, we slacken the tightening of the three pulley mounting bolts. Alternately inserting a screwdriver between the bolts to prevent turning.
We remove the pulley.
Using a 13 mm socket with an extension, we unscrew the two bolts of the pump body lower mounting to the cylinder block.
We unscrew one bolt of the pump body upper mounting.
We remove the coolant pump.
A gasket is fitted under the pump body. When fitting, we replace the gasket.
We remove the flywheel and the clutch housing cover;
Using a 10 mm spanner, we unscrew the four bolts securing the clutch cover.
Using a 17 mm socket, we unscrew the six bolts securing the flywheel.
We lock the shaft against turning with a mounting pry bar.
We remove the washer, remove the flywheel.
Next we remove the cylinder head together with the receiver, the inlet pipe and the exhaust manifold;
the timing drive chain, the chain tensioner shoe, the crankshaft sprocket;
Using a 10 mm socket, we unscrew the six bolts securing the crankshaft rear seal retainer to the cylinder block.
We prise off the retainer lugs with a screwdriver and remove it together with the oil seal.
We withdraw from the seal cover two bolts with square heads.
We remove the gasket.
Using a 10 mm spanner, we unscrew the bolt securing the oil separator drain pipe bracket and remove the bracket.
Using a 14 mm socket, we unscrew the two nuts securing the connecting rod cap.
We tap with a plastic hammer on the surfaces of the connecting rod cap.
We remove the connecting rod cap.
We withdraw the lower connecting rod bearing shell.
Resting on the ends of the connecting rod bolt shanks, we slide the lower connecting rod end off the crankshaft journal.
Resting the wooden handle of a hammer against the lower connecting rod end, we push the piston into the cylinder.
We withdraw the piston with the connecting rod from the cylinder. We also withdraw the pistons from the other cylinders.
We spread the upper compression ring gap.
We remove the upper compression ring.
We also remove the lower compression ring.
We withdraw the two discs of the oil scraper ring.
We remove the oil scraper ring expander.
To remove the piston from the connecting rod, we prise off the piston pin circlip with a screwdriver.
We extract the circlip from the groove of the piston boss. In the same way we withdraw the second circlip.
Having slid the piston pin, we extract it from the holes in the piston and in the connecting rod end.
We remove the piston from the connecting rod.
Using a 17 mm socket, we unscrew the two bolts securing the crankshaft main bearing cap.
If the parts are to be reused, they must be marked.
We remove the main bearing cap.
We withdraw the main bearing shells from the cap. We also remove the other main bearing caps.
We extract the crankshaft from the block.
We withdraw the half-rings from the grooves of the cylinder block rear support.
We withdraw the upper main bearing shells of the crankshaft from the cylinder block supports.
We prepare the engine for inspection and fault diagnosis.
