Engine overhaul

This operation is carried out with the engine removed (see previous operation) and separated from the gearbox, after removing the starter motor. During disassembly, take care to mark all parts and their matching positions for reassembly.

SPECIAL POINTS FOR REMOVAL

Observe the following points:

• remove and disassemble each connecting rod and piston assembly, and store them without mixing them up.
• gradually loosen the crankshaft main bearing caps and remove them, with their bearing shells and crankshaft end-float shims, storing them without mixing them up.
• thoroughly clean all parts, gasket surfaces, contact surfaces, bolts coated with thread locker, and the lubrication and cooling passages. We recommend avoiding scraping the parts; instead use a suitable chemical stripper for cleaning (for example Loctite Décapjoint).
• inspect the parts, then machine or replace those that are damaged, according to their specifications and spare parts availability. Refer to the 'Specifications' for this.

SPECIAL POINTS FOR REFITTING

Observe the following points:

• during reassembly, always lubricate all contact parts with the recommended engine oil,
• always replace self-locking nuts and sealing gaskets,
• observe the specified torques and tightening sequences.
• if necessary, determine the class of the crankshaft bearing shells to fit (see 'Specifications'),
• fit the crankshaft end-float shims on the centre main bearing,
• check the crankshaft end float and make sure the crankshaft turns freely. If the end float is incorrect, replace the end-float shims,
• fit the lubricated connecting rod and piston assemblies into the cylinder block.

Cylinder block and moving parts

1. 1
   Cylinder block
2. 2
   Coolant drain plug on cylinder block: 3 daN.m
3. 3
   Cap
4. 4
   Crankshaft seal carrier
5. 5
   Bolts: 0.9 daN.m
6. 6
   Timing cover
7. 7
   Seal
8. 8
   Bolts: 1 daN.m
9. 9
   Crankshaft main bearing cap
10. 10
    Bolts:

• 1st pass: 5.5 daN.m
• 2nd stage: 90°.

1. 1
   Piston underside oil jet
2. 2
   Balance shaft
3. 3
   Intermediate plate
4. 4
   Crankshaft gear
5. 5
   Crankshaft
6. 6
   Key
7. 7
   Accessory drive pulley
8. 8
   Bolts:

• 1st pass: 20 daN.m
• 2nd stage: 90°.

1. 1
   Crankshaft bearing shells
2. 2
   Crankshaft end-float shims
3. 3
   Flywheel (manual gearbox)
4. 4
   Ring gear (automatic gearbox)
5. 5
   Bolts:

• 1st pass: 4.5 daN.m
• 2nd stage: 90°.

1. 1
   Connecting rod
2. 2
   Connecting rod bearing shells
3. 3
   Bolts:

• 1st pass: 0.5 daN.m
• 2nd pass: 2.5 daN.m
• 3rd stage: 90°.

1. 1
   Connecting rod small-end bushing
2. 2
   Piston pin
3. 3
   Circlip
4. 4
   Piston rings.

Engine and gearbox mountings

1. 1
   Engine mounting bush
2. 2
   Bolt M10 x 100
3. 3
   Nut: 5.5 daN.m
4. 4
   Bolt M8 x 12: 5.5 daN.m
5. 5
   Bolt M12 x 110: 8 daN.m
6. 6
   Torque rod
7. 7
   Bolt M8 x 20: 2 daN.m
8. 8
   Front left engine mount
9. 9
   Bolt M10 x 35: 5.5 daN.m
10. 10
    Rear left engine mount.

Exhaust

1. 1
   Without particulate filter
2. 2
   With particulate filter.
3. 3
   Heat shields
4. 4
   Turbocharger
5. 5
   Holder
6. 6
   Bolts: 3 daN.m
7. 7
   Sealing gaskets
8. 8
   Exhaust manifold
9. 9
   Screw: 1.4 daN.m
10. 10
    Lambda sensor: 5 daN.m
11. 11
    Pre-catalytic converter
12. 12
    Catalytic converter
13. 13
    Silencer
14. 14
    Rear pipe
15. 15
    Differential pressure sensor
16. 16
    Front pipe
17. 17
    Particulate filter
18. 18
    Temperature sensor
19. 19
    Pressure sensor line.