Disassembly
1. Stand the engine on a trolley.
2. Remove the starter motor:
^ Disconnect the alternator lead, the positive lead and the yellow lead to the solenoid from the ignition switch.
^ Remove the outer securing bolt and the steady bar from the inlet manifold.
^ Remove the inner securing bolt and lift off the motor.
3. Remove the clip from the throttle linkage and the clip from the inlet manifold side bracket and disconnect the kickdown cable.
4. Remove the steady bar from the RH side of the inlet manifold.
5. Remove the engine mounting/support bearing bracket complete with the tube and inner drive-shaft joint.
6. Remove the bottom bolt from the engine gearbox flanges.
^ Install a second nut onto the stud to lock the first, and undo the stud.
^ Install bracket 83 94 454, or equivalent and lift the engine onto an engine stand.
7. Remove the gearbox breather valve.
8. Undo the three bolts securing the flywheel to the torque converter by means of the crankshaft pulley, rotate the flywheel to bring each securing bolt, in turn, in line with the opening in the back-plate.
9. Immobilize the torque converter using gaps 87 91 816, or equivalent.
10. Install lifting beam 87 91 451, or equivalent onto the gearbox. Undo the securing bolts and lift off the gearbox.
11. Remove the two-part exhaust manifold, inner section first and outer section last. Note the spacer sleeves on the bolts in the outer section.
12. Remove the bracket for the AC compressor.
13. Remove the water pump complete with sleeve end O-rings.
14. Remove the front engine mounting.
15. Remove the oil filter and adaptor. Note the seal.
CAUTION: The engine mounting incorporates a locating groove and must therefore be installed before the adaptor.
16. Remove the inlet manifold complete with engine wiring loom and throttle housing:
^ Remove the bracket for the dipstick tube
^ Disconnect the preheater hoses from the throttle housing
^ Unplug the leads from the alternator
^ Disconnect the crankcase breather hoses from the camshaft cover
^ Disconnect the fuel line from the fuel pressure regulator
^ Undo the eight securing bolts and lift off the inlet manifold
17. Remove the alternator.
18. Remove the top engine mounting (four bolts).
19. Remove the steering servo pump complete with bracket and idler-wheel pulley.
20. Remove the pipe connecting the water pump to the heater-box hoses. Release the clips holding the crankshaft-sensor leads and snip through the tie securing the leads to the pipe.
21. Remove the belt tensioner complete with bracket and idler-wheel pulley.
22. Align the mark (0°) on the flywheel with that on the end plate and check that the camshafts are also in line with the setting marks.
23. Disconnect the lead from the earthing point, release the clip on the fuel-pressure regulator bracket and remove the ignition module (cartridge).
24. Remove the camshaft cover.
25. Install locking segment 83 93 987, or equivalent as shown. Remove the crankshaft pulley.
26. Remove the flywheel locking segment and then the flywheel.
27. Remove the chain tensioner: remove the adjusting screw first to enable a socket (27 mm) to be used.
28. Remove the camshaft sprockets and position the chain where it will not obstruct removal of the cylinder head.
29. Remove the cylinder head (note the bolts at the timing end).
30. Swivel the engine into a suitable position and remove the sump. Do not remove the guide sleeve from the casting.
31. Remove the timing cover complete with oil pump, crankshaft sensor and reducing valve. Note that the bolts are different lengths.
32. Remove the top guide for the balance-shaft chain.
33. Remove the chain tensioner and pivoting guide.
34. Remove the idler-wheel sprocket and the balance-shaft chain.
35. Remove the oil pump drive dog and sprocket from the crankshaft.
36. Remove the pivoting chain guide for the timing chain.
37. Remove the fixed chain guide for both the timing and balance-shaft chains.
38. Remove the timing-chain guard followed by the chain and sprocket.
CAUTION: Observe the utmost care when removing the balance shafts to avoid damaging the inner bearing shells.
39. Remove the balance shafts complete with sprockets and bearing housings.
40. Remove the end plate.
CAUTION: When dismantling bearing caps and bearings, store them carefully in order, so that they can be reassembled in their original positions.
41. Swivel the engine into a convenient position and remove the big-end bearing caps.
42. Remove the main bearing caps.
43. Lift out the crankshaft.
44. Remove all the bearing shells, for both the main bearings and big-end bearings. Also remove the two thrust washers from the No. 3 main bearing.
45. Press or carefully tap the pistons out of the bores.