Remove the alternator and coolant pump drive belt, then the alternator with the bracket. Disconnect the heater fluid supply line from the pump and the outlet manifold and remove the coolant pump. Remove the cooling jacket outlet pipe and the heater fluid drain line from the cylinder head.
Using tool A.60312, unscrew and remove the oil filter with the gasket (Fig. 45). Unscrew sensor 20 (see fig. 24) oil pressure indicator lamp, remove the crankcase ventilation breather cover, oil pan and oil pump. Remove the oil separator drain pipe retainer attached to the lower plane of the cylinder block and take out the crankcase ventilation oil separator.
Remove the crankshaft pulley, securing the flywheel with the A.60330/R lock (see fig. 48) and unscrewing the ratchet with the A.50121 key.
Remove the cylinder head cover and the camshaft chain drive cover. Then unscrew the bolts securing the camshaft sprockets and the oil pump drive shaft. Loosen the cap nut 5 (Fig. 46) of the chain tensioner 1, unscrew the nuts 4 securing it to the cylinder head, remove the tensioner and, having unscrewed the bolt 2, remove the shoe 3 of the chain tensioner. Unscrew the chain limiting pin, remove the oil pump and camshaft drive sprockets and take out the chain.
Loosen the nuts of the studs securing the camshaft thrust flange. Having unscrewed the nuts, remove the camshaft bearing housing. Unscrew the nuts of the studs and, having removed the thrust flange, carefully, so as not to damage the surface of the bearing housing supports, take out the camshaft. Unscrew the bolts securing the cylinder head and remove it together with the exhaust manifold and intake manifold.
Using key 4 (Fig. 47), unscrew the two bolts 2 securing the thrust flange 1 of the oil pump drive shaft, remove the flange and take shaft 3 out of the cylinder block. Using universal puller A.40005/1/7 from set A.40005, remove the sprocket from the crankshaft. Unscrew the nuts of the connecting rod bolts, remove the connecting rod caps and carefully remove the pistons with connecting rods through the cylinders. When performing this operation, it is recommended to mark the piston, connecting rod, and main and connecting rod bearing shells so that they can be installed in their original place during assembly.
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Install retainer 5 (Fig. 48) into the cylinder block hole, unscrew bolts 3 with key 1, remove washer 4 and flywheel 2 of the crankshaft, and then the front cover 6 of the clutch housing. Using ejector A.40006 (in Fig. 49) remove the gearbox input shaft bearing from its socket in the crankshaft. Remove the crankshaft rear oil seal holder 2.
Unscrew the main bearing cap bolts, remove them together with the lower bearing shells, then remove the crankshaft, upper bearing shells and thrust half rings on the rear support.