Note: When disassembling, mark the removed parts that are suitable for further use so that when reassembling, they can be installed in their original locations and positions.
Remove the engine. Place the washed and cleaned engine on a disassembly stand. Remove the oil filter. Remove the cylinder head cover, intake manifold, exhaust manifold and turbocharger (depending on the configuration). Remove the cylinder head as shown below. Remove the oil pan.
Remove the clutch housing assembly with the pressure plate. Remove the pistons with connecting rods. To do this:
- secure the cylinder block to the stand;
- apply timing marks to connecting rods, connecting rod caps and corresponding cylinders;
- unscrew the connecting rod cap bolts;
- make sure that there are alignment marks on the outer surface of the connecting rods and connecting rod caps;
- remove the pistons with connecting rods from the cylinders.
Remove the connecting rod bearing shells and check their wear as described below. If the shells are suitable for further use, mark their positions ("top", "bottom") and mark the corresponding connecting rods. Remove the piston pin retaining ring with pliers and push the pin out of the connecting rod upper head with a drift. Loosen the crankshaft oil seal holders mounting bolts and remove the holders together with the oil seals using two screwdrivers inserted behind the two projections intended for this purpose. Before removing the main bearing caps, check the axial movement of the crankshaft, which must correspond to the values specified in subsection "Crankshaft and flywheel". Loosen the main bearing cap fastening bolts and remove the caps together with the lower liners. Remove the crankshaft and upper liners from the bearing seats. The main bearing caps are marked with numbers from 1 to 5, indicating the order in which they were installed during engine assembly. If the main bearing shells are to be used again, apply alignment marks to them as specified for the connecting rod bearing shells, with markings on the corresponding main bearing caps. Remove the intermediate shaft thrust bearing together with the oil seal and remove the intermediate shaft.
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