Disassembly

1. Remove the support bearing bracket with pipe and the internal universal joint.
2. Remove the bracket for the engine wiring harness. Disconnect and remove the starter motor.
3. Remove the plastic plug under the starter motor and remove the torque converter bolts (automatic transmission). Pull the torque converter forward gradually by turning the crankshaft with the pulley.
4. Remove the cover plates and immobilize the torque converter using tool 87.92.293.(automatic transmission).
5. Disconnect the speedometer sensor connector and remove the gearbox.





6. Remove the coolant intake, the thermal shield above the front exhaust manifold and the secondary air injection pipe.
7. Install holder 83 94 751 to the engine and lift the engine over to work stand 78 74 878, or equivalents.
8. Remove the torque arm engine mounting and lift off the multi-groove belt.
9. Remove the right-hand engine mounting bracket.
10. Remove the belt tensioner and disconnect and remove the generator. Do not forget to remove the lead to the oil pressure sensor from the generator.





11. Disconnect the crankcase ventilation hose from the intake manifold.
12. Remove the hose for preheating the throttle body.
13. Disconnect the temperature sensors and the ignition coil and remove the ground leads from the bracket.
14. Disconnect the camshaft position sensor, the leads to the injectors, the oil pressure sensor and the rear knock sensor.
15. Remove the upper section of the intake manifold complete with the cable assembly.





16. Drain the oil and tighten the drain plug to 55.Nm (41.ft. lbs.).
17. Remove the dipstick level tube.
18. Remove exhaust manifolds and take out gaskets.
19. Remove the crankshaft position sensor.
20. Remove the knock sensors. Note the position of the rear knock sensor lead.
21. Remove the ignition coil complete with ignition leads and remove the bracket for the ignition coil and the accelerator linkage.
22. Remove the oil filter arid disconnect the oil lines from the cylinder block.





23. Remove the center intake manifold with fuel rail.
24. Remove the lower intake manifold.
25. Disconnect the coolant pipe and remove the thermostat housing complete with thermostat.
26. Remove the coolant bridge. Be careful with the copper gasket.
27. Remove the crankcase breather housing.
28. Remove spark plugs and the valve caps complete with gaskets.





29. Remove coolant pump pulley and the crankshaft pulley and lift off the timing cover.
30. Zero the engine, mark the direction of rotation of the toothed belt, release the tension and remove. Turn the crankshaft back to 60° BTDC.

CAUTION: The camshafts must not be rotated as the valves may hit the pistons or each other and be damaged. The crankshaft may only be turned between 0° and 60° BTDC when both the cylinder heads' camshafts are immobilized with immobilizing tools.

31. Hold the camshafts with a box wrench and remove the camshaft sprockets.

CAUTION: The open ended wrench used as a holding tool to remove the camshaft sprockets must not have jaws that are too long. There is a risk of damaging the casting so that the tappet locks.

32. Remove the holder with the tensioning pulley and the upper adjusting pulley. Remove the lower adjusting pulley.
33. Remove the coolant pump, be careful with the O-ring.

NOTE: There is quite a lot of coolant left in the engine. Always have a collecting tray under the engine.

34. Remove the rear timing cover and the camshaft position sensor.





35. Remove the bearing caps from the exhaust camshafts by undoing the bolts in steps of 1/2 to 1 turn. It is important to finish the removal at the bearing cap where the depressor is under compression, and lift out the camshafts. Note the markings on the camshaft bearing caps.

NOTES:
^ Intake camshafts can remain in place.
^ The camshafts must come away from the bearing seats evenly.

36. Remove the valve depressors and store them in valve stand 83.93.787.so that they do not become mixed. Insert protective sleeves 83 95 022, or equivalent.
37. Undo the cylinder head bolts, see illustration, in steps of 1/4 to 1/2 a turn. Remove the cylinder heads. Be careful when putting them down as the intake camshafts remain in place and carelessness can cause the valves to bend.





38. Disconnect the lines from the heat exchanger, being careful with the copper-gaskets, and remove the heat exchanger cover complete with the heat exchanger. Remove the gasket.

NOTE: The fitting position.

39. Mark the pistons with cylinder number.





40. Turn the engine and remove the oil pan, the oil pipe and the anti-slosh baffle.
41. Attach support 83 95 063, or equivalent remove the toothed belt sprocket from the crankshaft and remove the oil pressure sensor.
42. Remove the oil pump and the gasket. take out the crankshaft seal.
43. Remove the flywheel or alternatively the drive plate.





44. Undo all big-end bearing caps and push or carefully tap the pistons in pairs from the cylinders. Start with 1 and 2.
45. Remove the main bearing member by first undoing the middle bolts on the long sides (4 pieces), see illustration, and screwing the adjusting sleeves up about 1/2 turn.

NOTE: If the adjusting sleeves are in the original position they don't need to be changed.

46. Remove remaining bolts. Note the assembly position of the main bearing member.
47. Dismantle all main bearing caps and lift out the crankshaft.

CAUTION: The aperture disc must be handled with great care.

48. Remove the perforated disc.
49. Remove all bearing shells for both the main bearings and the big-end bearings.