Attention.
- Use protective coatings to prevent damage to painted surfaces.
- To avoid damage to the cylinder head, wait until the coolant temperature has dropped to room temperature before removing it (20°C).
- When working with the metal gasket, take care not to bend it or damage its contact surfaces.
- Disconnect connectors carefully while holding the connector with your hand to avoid damage.
Note:
- Label all wires and hoses to avoid errors when reconnecting.
- Turn the crankshaft pulley so that the #1 cylinder piston is at top dead center (TDC).
1. Remove the engine complete with gearbox.
2. Install the engine on the stand.
3. Remove the intake and exhaust manifolds.
4. Remove the timing chain.
5. Remove the cylinder head.
6. Remove the high pressure fuel pump.
7. Remove the coolant pump.
8. Remove the flywheel (vehicles with manual transmission).
9. Remove the drive disc (IN) and intermediate plate (A) (vehicles with automatic transmission).
10. Remove the encoder (A) and rear seal housing (IN) assembled.
Attention.
- The rear seal housing must not be reused.
- Do not place magnetic materials near the encoder.
- Be careful not to scratch or damage the encoder.
- Do not allow sealant or other harmful materials to interact with the encoder.
11. Remove the oil pump module.
12. Remove the frame (A) ladder type.
13. Remove the pistons and connecting rods as an assembly:
Using a special tool, remove carbon deposits from the top of the cylinder.
Remove the cover (A) connecting rod.
Note: Mark the connecting rods and caps so they can be reassembled in their original position and direction.
Push the piston and connecting rod with the upper bearing through the top of the cylinder block.
Note:
- Connecting rods and bearing caps must not be disassembled.
- Position the piston and connecting rod in the correct order.
- Mark the piston and connecting rod so that they can be reassembled in their original position and direction.
14. Remove covers (A) main bearings, then remove the crankshaft (IN) from the cylinder block, taking care not to damage the necks.
Note:
- Position the main and thrust bearings in the correct order.
- Caps and main bearings must not be disassembled.
15. Remove the oil nozzle (A).
16. Check fit between piston and pin:
Try to move the piston on your finger back and forth. If movement is not possible, replace piston and pin.
17. Remove piston rings:
Using a ring expander, remove the two compression rings (A).
Remove oil ring and spring (IN) manually.
Attention. Do not use excessive force to remove the oil scraper ring from the piston. This can damage the oil scraper ring.
Note: Position the piston rings in the correct order.
18. Disconnect the connecting rod from the piston:
Remove retaining ring (WITH) from the piston.
Remove the pin from the piston using a press.
Disassemble the piston (F) and connecting rod (E).