You will need: keys «for 8», «on 10», «at 13», «at 17», interchangeable heads «on 10», «at 13», «at 17», hex socket wrenches «by 5», TORX E10 key, knob, pliers, screwdriver, set of flat probes, micrometers (with measurement limits 0–25, 25–50 and 75–100 mm), caliper, dial gauge with indicator stand, torque wrench, oil filter puller.
Note. If possible, work on a special turntable that provides access to the engine from all sides, since it is very difficult to fix the engine from moving when unscrewing fasteners tightened with a large torque.
1. Remove the engine from the car (see «Removal and installation of the engine»).
2. Place the engine on firm stands.
3. Disconnect the gearbox from the engine (see «Removal and installation of a transmission»).
4. Remove the cylinder head (see «Replacing the cylinder head gasket»).
5. Key «at 13» unscrew the three bolts securing the bracket of the front support of the power unit to the cylinder block..
6.... and remove the bracket.
7. Remove the oil filter (see «Changing engine oil and oil filter»).
8. Key «on 10» unscrew the two bolts securing the coolant pump inlet pipe to the cylinder block..
9.... and remove the pipe..
10.... and a sealing gasket.
11. When assembling the engine, install a new seal.
12. Remove water pump and seal (see «Water pump replacement»).
13. Key «for 8» remove the six bolts securing the clutch to the flywheel..
14.... and remove the clutch.
15. Mark the relative position of the flywheel and crankshaft.
16. head «at 17» Remove six flywheel bolts..
17.... and remove the flywheel.
18. Key «on 10» remove the sixteen oil pan mounting bolts..
19.... and remove the oil sump along with the gasket.
20. Key «on 10» unscrew the three bolts securing the oil receiver..
21.... and remove the oil receiver.
Note. Please note: a rubber sealing ring is installed in the groove of the receiver pipe. A badly compressed, hardened or torn ring must be replaced.
22. Pry with two screwdrivers..
23.... and remove the toothed pulley from the toe of the crankshaft.
24. Remove the key from the groove on the toe of the crankshaft.
25. Key «on 10» Remove the six oil pump mounting bolts and remove the pump.
26. Key «on 10» remove the six bolts securing the crankshaft rear oil seal holder..
27.... and remove the holder with the gland installed in it..
28.... and a sealing gasket.
29. Turn the crankshaft so that the piston to be removed is at BDC (bottom dead center). Using a TORX E10 wrench, unscrew the two connecting rod cap bolts.
30. Remove the connecting rod cover. If the dismantling of the cover is difficult, first remove it with light blows of a hammer. The cylinder number may not be visible on the cap, in which case mark the cap with the cylinder number.
31. Push the connecting rod with a hammer handle into the cylinder..
32.... and carefully remove the piston with the connecting rod from the cylinder. At the same time, make sure that the lower head of the connecting rod does not touch the cylinder mirror, otherwise the mirror may be damaged. Remove the rest of the pistons in the same way.
Note. If you plan to remove the piston from the connecting rod, mark the piston with the cylinder number so as not to mix up the pistons during installation. On the connecting rod, as well as on the cover, the cylinder number is stamped; if it is not visible, mark the connecting rod.
33. Key «at 17» unscrew the two bolts of the bolt of the five main bearing caps..
34.... and remove the covers.
Attention! The main bearing caps are marked with notches according to the cylinder numbers. If these marks are not clearly visible, be sure to additionally mark the covers in order to reinstall them in their original places: the covers are not interchangeable (cylinder block machined together with covers).
35. Remove the crankshaft.
36. Remove the thrust half rings installed in the grooves of the middle bearing of the crankshaft.
37. Remove the liners from the main bearing caps..
38.... and the beds of the block. If it is not intended to replace the liners, when removing, mark the liners on the non-working side with respect to covers and beds.
39. Remove the piston rings with a special puller. If it is not there, remove the rings from the piston by carefully spreading the locks of the rings.
40. Inserting a screwdriver into the recess on the piston boss..
41.... remove the retaining ring holding the piston pin. Remove the second snap ring in the same way.
42. Using a suitable mandrel, push the pin out of the piston and remove the piston from the connecting rod.
43. Remove the liners from the connecting rod..
44....and out of his lid. If the liners remain on the crankshaft, remove them from the shaft. If the bushings are not to be replaced, mark them on the non-working surface with respect to the connecting rods and caps when removing them.