Engine Disassembly
1. On models equipped with A/C, remove compressor mount.
2. On all models, remove turbocharger and turbocharger ducting pipes.
3. Mount engine onto suitable engine stand. Do not rest engine on oil pan because of possible damage to oil pump.
4. Remove starter, distributor, spark plug wiring harness and alternator.
5. Remove intake manifold, power steering pump, motor mounts, coolant inlet housing, oil filter, dipstick and accessory drive belts.
6. Remove clutch and pressure plate. Use tool No. 35327 or equivalent to hold flywheel.
7. Remove water pump, then the crankshaft pulley.
8. Remove valve cover, then the upper part of timing chain cover.
9. Remove oil level sending unit, oil pan, flywheel plate, and flywheel.
10. Remove power steering pump bracket, then the lower part of timing chain cover.
11. Remove oil pump and oil pump drive chain.
Fig. 1 Unloading timing chain tensioner:
12. Unload timing chain tensioner, as follows:
a. On Brampton tensioner (A) Fig. 1 remove bolt (10), then release tension using a suitable Allen wrench (11).
b. On Winklofer tensioner (B), Fig. 1, push in shaft (12) using suitable tool, then rotate tool to the right.
13. Remove chain tensioner, both fixed pads, camshaft pinion, and timing chain.
14. Remove crankshaft pinion, using a suitable puller.
15. Remove cylinder head bolts, then the head, using ``L'' handles, tool No. J35339 or equivalent.
16. Remove connecting rod bearing caps. Mark position of bearing caps and connecting rods to facilitate installation. Place mark on side closest to oil filter.
17. Remove piston and rod assemblies, then the main bearing caps and crankshaft.
Fig. 2 Camshaft retaining clamp:
18. Remove cylinder head rear inspection plate (1), Fig. 2, then camshaft retaining clamp (2).
Fig. 3 Removing circlips:
19. Loosen rocker arm adjusting screws, then push spacer (3), Fig. 3, to one side and remove circlips (4) for each rocker arm.
20. Remove rocker arm shafts from cylinder head, then the rocker arms, springs and spacers from cylinder head.
21. Pull camshaft from cylinder head.
22. Remove valve springs and valves, then the valve stem seals, using tool No. J28612 or equivalent.