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Disassembly and Assembly of Subassemblies > < In-vehicle Repair|Engine

Ikon 1999 (01.2000-)

Engine - 1.3L Endura-E (HCS) - Engine Ikon 1999 (01/2000-)
Disassembly

Special Tool(s)

Immobilizing tool, flywheel

303-393 (21-168)

Assembly stand

303-435 (21-187)

Mounting frame for 303-435

303-435-02 (21-050 A)
General Equipment
Oil filter strap wrench
Micrometers
Two-legged puller
Three-legged puller
Torque wrench
Internal micrometer
Materials
Name
Specification
Plastigage
obtainable from: Replacement Services Limited, 30 Euston Street, Freemans Industrial Estate, Leicester, LE2 7ST. 
Engine oil
WSS-M2C912-A1 
Sealer, oil pan to cylinder block
WSE-M4G323-A4 
Lubricant for spark plugs ('Never Seeze')
ESE-M1244-A 
Silicone grease
ESE - M1C171 - AA 

Disassembly

All Vehicles
  1. Remove the exhaust manifold heat shield.

  1. Detach the catalytic converter from the cylinder block.
    1. Detach the upper mounting (if equipped).
    1. Detach the lower mounting.

  1. Detach the exhaust manifold and the catalytic converter.

  1. Mount the engine with the mounting bracket on the assembly stand.

  1. Remove the alternator (four bolts).

  1. Detach the generator bracket with belt tensioner and idler pulley (if equipped).

  1. Disconnect the ignition cables.
    • Pull off the spark plug connectors.

  1. NOTE:
    NOTE:Only loosen the bolts, do not remove them.
    Remove the clutch and loosen the flywheel bolts.
    1. Mount the special tool.
    1. Remove the clutch.
    1. Loosen the flywheel bolts.

  1. Detach the ancillary components.
    1. Drain off the engine oil.
    1. Remove the oil filter.
    1. Detach the DIS ignition coil (two bolts).
    1. Detach the oil dipstick tube and pull it out of the cylinder block.

  1. Detach the ancillary components.
    1. Pull out the plugs of the camshaft position sensor (CMP sensor) and the oil pressure switch.
    1. Remove the oil pressure switch.
    1. Remove the oil pump (two bolts, one nut). Remove the gasket.
    1. Remove the intake manifold complete (six bolts). Remove the gasket.

  1. Remove the coolant pump pulley.

  1. NOTE:
    NOTE:Do not remove the gasket.
    Remove the coolant pump.

  1. NOTE:
    NOTE:If necessary use a three-legged puller to pull off the pulley. If a puller is being used, check that the pulley bolt is properly seated to avoid damaging the crankshaft.
    Remove the crankshaft pulley.
    1. Remove the single screw.
    1. Remove the pulley.

  1. Remove the cylinder head cover.
    1. Remove the oil filler cap. Detach the crankcase ventilation hose.
    1. Remove the cylinder head cover (four bolts and four washers). Remove the gasket.
    1. Remove the rocker shaft (four bolts).
    1. Remove the valve push rods and put them aside in order.
Vehicles 12/1997 onwards
  1. Remove the thermostat housing.
    1. Remove the thermostat housing.
    • Remove the thermostat and gasket.
    1. Remove the spark plugs.
All vehicles
  1. CAUTION:
    CAUTION:Mark the bolts for re-use with a center punch. The bolts can be re-used once. Unscrew the bolts in the sequence shown.
    Remove the cylinder head (ten bolts).

  1. Remove the flywheel.
    • Remove the screws.
    • Remove the special tool.

  1. NOTE:
    NOTE:A steel oil pan shown, the aluminium oil pan is similar.
    NOTE:
    NOTE:Only remove the oil pan downwards, so that no abraded particles or oil sludge enter the engine.
    Remove the oil pan (18 bolts).

  1. Remove the crankshaft rear oil seal carrier.
    • Remove the gasket.
    • Drive out the oil seal onto a flat surface.

  1. Remove the timing cover.
    • Remove the gasket.
    • Drive out the oil seal onto a flat surface.

  1. Remove the timing chain.
    1. Detach the oil slinger ring from the crankshaft.
    1. Remove the timing chain tensioning arm from the pin of the front main bearing.
    1. Detach the timing chain tensioner from the cylinder block (two bolts).
    1. Undo the camshaft sprocket bolts and remove the camshaft position sensor (CMP sensor) sender. Remove the camshaft sprocket with the timing chain.

  1. CAUTION:
    CAUTION:Position the engine upright.
    Remove the camshaft.
    • Rotate the camshaft through 360 degrees, to bring the valve tappets into TDC position.
    • Carefully remove the camshaft from the cylinder block.

  1. NOTE:
    NOTE:Make sure that the valve tappets are set in order to one side.
    Remove the eight valve tappets.

  1. Pull off the crankshaft sprocket with a two-legged puller.

  1. NOTE:
    NOTE:Carefully remove carbon deposits with a plastic scraper. Do not damage the piston ring running surfaces.
    NOTE:
    NOTE:Set the connecting rods, big-end bearing caps and bearing shells aside in order.
    Remove the pistons with the connecting rods.
    1. Detach the big-end bearing caps.
    1. Press the connecting rod and piston out of the cylinder block.

  1. NOTE:
    NOTE:Lay the main bearing caps and bearing shells in order to one side. Align the main bearing and thrust half washers. Mark the position of the thrust half washers.
    Remove the main bearing caps.
    • Take out the bearing shells and thrust half washers.
  1. Remove the crankshaft.

  1. Remove the crankshaft position sensor (CKP).

Disassembly and Assembly of Subassemblies > < In-vehicle Repair|Engine