SAMAND

Service Manual
Engine: XU7JPL3
 Product:
Chapter: Section: SAMAND XU7JPL3
XU7JPL3Engine

SAMAND
Service Manual

Foreword:

This Service Manual contains descriptions of the following categories for the
Samand:

Engine: XU7JPL3

This manual should be used as service manual and s workbook for training
instructors and technicians. We reserve the right to introduce change without
prior notice.

I
 Important

Warning
Lengthy and repeated contact with mineral oil removes
the natural oils of your skin, drying it out and causing
irritation. If oil has been swallowed, do not provoke
vomiting. Call a doctor.
Waste oil may contain harmful impurities which can
cause skin cancer. Always use suitable protection and
thoroughly wash your hands and other areas of bare
skin that have come into contact with the oil.
Observe the following safety rules:
• Avoid lengthy and repeated contact with oil,
grease, etc. And especially waste oil.
• Wear protective clothing, including impermeable
gloves, if possible.
• Do not put oily rags into your pockets.
• Do not wear clothes that have been soiled by oil,
especially items of underwear. Clothes must be
washed at regular intervals.
• Do not wear oily shoes.
• Clean open sores immediately and cover them
with an adhesive bandage, sticking plaster, etc.
• Use barrier cream. Apply it to your exposed skin
before each working period so that it will be easier
for you to wash oil and grease off afterwards.
• Remove oil from your face and hands, etc. by
washing them thoroughly with soap and water
(special skin cleansers and a nailbrush will help).
• Do not use petrol, paraffin, diesel oil, thinner or
solvents to remove oil from any part of your body.
• If you notice any changes in your skin, consult a
doctor without delay.
• If possible, clean the parts before starting work.
• If there is a danger of oil getting into your eyes,
wear protective goggles, a visor or a face mask.
Eye-washing equipment must also be readily
available.
 Contents
Engine
Technical data
General data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lubricating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Special tools
Cross piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Lifting hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ball joint extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AY hub clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Left-hand output oil seal fitting drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Right-hand output oil seal fitting drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Piston liner retaining clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Piston liner retaining clamp bolts M11x150x60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Camshaft gear setting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Camshaft levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Camshaft gear stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Camshaft oil seal fitting drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Crankshaft setting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Belt tension measuring equipment seem c.Trionic type 87. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Crankshaft pulley extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Flywheel stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure testing kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Right-hand crankshaft oil seal fitting drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Left-hand crankshaft oil seal fitting drift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Crossbeam and adjusting screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Crossbeam support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Gudgeon pin fitting tool base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Gudgeon pin fitting tool handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Gudgeon pin fitting tool guide end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Gudgeon pin fitting tool Piston locater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Plastigauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Number 5 main bearing seals fitting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Technical description
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Connection rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Crankshaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cylinder head and camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Adjustment and replacement

Engine remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Drivebelt and tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Dipstick tube remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cylinder head cover remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Cylinder head remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Cylinder head refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Camshaft and followers remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Valve clearance checking and adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Camshaft sprocket and oil seal replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Valve remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Timing belt and covers remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Timing belt tensioner - sprockets remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Engine oil and filter renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Oil pressure check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Sump remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Oil pump and deflector remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Flywheel remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Crankshaft oil seal remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Engine/gearbox mountings remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Engine overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Piston and connecting rod overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Crankshaft and main bearing overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Cylinder liner overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Cylinder liner protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Engine build up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Initial startup after overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
 1

Engine
Technical data
General data
Engine type XU7 JP
Cylinder bore 83mm
Stroke 81mm
Swept volume 1761 cm3
Direction of rotation Clockwise

W72S001

Engine block
Group A: 83.000-83.010mm
Group B: 83.010-83.020mm
Group C: 83.020-83.030mm
Liner protrusion above block 0.03-0.10mm
mating surface:
Maximum difference between 0.05mm
two liners:

W72S002

Cylinder head
Height 157.4 to 157.7mm
Maximum gasket face distortion 0.07mm

W72S003
4 Technical data

Pistons
Classification of pistons and cylinder liners
The piston classification code is stamped on the piston
crown. The codes for servicing are:
A
B
C
The piston liner classification is marked on the liner top face.

Piston sizes
Group A 82.960±0.007mm
Group B 82.970±0.007mm
W72S004
Group C 82.980±0.007mm

Piston rings
End gap:
Chromed radius ring 0.30-0.50mm
Taper ring 0.30-0.50mm
Scraper ring 0.30-0.50mm
Note: These figures are typical for this type of engine.
No exact values were available.

Gudgeon pin
The gudgeon pin is a interference fit with the
connection rod.

W72S005

Connecting rods
Maximum permissible weight variation per set 13g

W72S006
 Crankshaft
General data
End float 0.07-0.32mm
Maximum journal out of round 0.007mm
Main bearing clearance 0.025-0.062mm
*Big end bearing running clearance 0.025-0.050mm

*Note: These figures are typical for this type of engine.

No exact values were available.

W72S007

Endfloat and half shells

A B
Standard 26.7+0.05mm 2.33-2.38mm
1st undersize 26.8+0.05mm 2.38-2.43mm
A 2nd Undersize 26.9+0.05mm 2.43-2.48mm
3rd Undersize 27.0+0.05mm 2.48-2.53mm

Oil seal contact surface

C C
Standard 90.0-0.054mm
1st undersize 89.8-0.054mm

W72S008

Crank journals and main bearing shells

D A B
Standard 60.0-0.016mm 1.842±0.003mm
B 1st undersize 59.7-0.016mm 1.992±0.003mm
C
Big end journals and bearing shells
C D
Standard 44.991-0.016mm 1.828+0.015mm
1st undersize 44.475.016mm 1.978+0.015mm
A
Note: The standard main bearing shells are identified
by green or yellow markings.

W72S009
6 Technical data

C
Valve gear
C
Inlet Exhaust
A: Length 108.59-108.99mm 108.20-108.54mm
B: Head diameter 41.6mm 34.5mm
C: Stem diameter 7.96-7.98mm 7.95-7-97mm
Valve clearance 0.20mm 0.40mm
A A

B B
W72S010

Camshaft
Timing belt driven
Number of bearings: 5

W72S011

Lubricating system
Oil capacity 3.9litres
Volume max and min 1.5litres
on dipstick
Grade of oil Multigrade
Viscosity SAE 10W/30 to
15W/50
Warning lamp comes 0.8bar
on at
Minimum oil pressure 5.3bar
at 4000rpm, engine
temperature 80ÞC

W72S012
Torque wrench setting
Big-end bearing cap nuts:
Stage 1 20 Nm
Stage 2 ?? Nm
Camshaft bearing cap nuts 15 Nm
Camshaft sprocket retaining bolt: 35 Nm
Crankshaft pulley retaining bolt 35 Nm
Cylinder head bolts:
Stage 1 60 Nm
Fully slacken then tighten to:
Stage 2 20 Nm
Cylinder head cover nuts/bolts 10 Nm
Left-hand engine mounting:
Mounting bracket to body bolts 25 Nm
Mounting stud 25 Nm
Centre nut 65 Nm
Engine to gearbox fixing bolts 45 Nm
Torque reaction link:
Mounting assembly-to-block bolts 45 Nm
Mounting bracket-to-mounting bolt 50 Nm
Mounting bracket-to-subframe bolt 50 Nm
Engine right-hand mounting:
Bracket-to engine bolts 45 Nm
Mounting bracket retaining bolts 45 Nm
Flywheel/driveplate retaining bolts 50 Nm
Front oil seal carrier bolts 16 Nm
Main bearing cap nuts/bolts:
Retaining nuts/bolts 54 Nm
Centre bearing cap side bolts 23 Nm
Oil pump retaining bolts 16 Nm
Sump retaining bolts 10 Nm
Timing belt cover bolts 8 Nm
Timing belt tensioner pulley bolt 20 Nm
Special tools
Cross piece
(-).0102D

T.(-).0102D

Lifting hooks
(-).0102G

T.(-).0102G

Ball joint extractor

(-).0709

T.(-).0709
10 Special tools

AY hub clamp
(-).0606AY

T.(-).0606AY

Left-hand output oil seal fitting

drift
(-).0317T

T(-).0317T

Right-hand output oil seal fitting

drift
(-).0317U

T(-).0317U
 Piston liner retaining clamp
(-).0132A1Z

T.(-).0132A1Z

Piston liner retaining clamp bolts

M11x150x60
(-).0153J

T.(-).0153J

Camshaft gear setting rod

(-).0153G

T.(-).0153G
12 Special tools

Camshaft levers
(-).0149

T00149

Camshaft gear stop

(-).0132Y

T.(-).0132Y

Camshaft oil seal fitting drift

(-).0132 T

T.(-).0132T
Technical Department

IKCO Export after sales services department Engine Ref. No :1303R00202721/1

 Crankshaft setting rod
(-).0153G

T.(-).0153G

Belt tension measuring

equipment seem c.
Tronic type 87.

T.SEEM87

Crankshaft pulley extractor

(-).0174

T.(-).0174
14 Special tools

Flywheel stop
9765.54

T.9765.54

Pressure testing kit

(-).1503.ZY

T.(-).1503ZY

Right-hand crankshaft oil seal

fitting drift
(-).0153D

T.(-).0153D
 Left-hand crankshaft oil seal
fitting drift.
(-).0153B

T.(-).0153B

Crossbeam and adjusting screw

(-).0911 A1

T.(-).0911A1

Crossbeam support
(-).0911 A2

T.(-).0911A2
16 Special tools

Gudgeon pin fitting tool base

(-).0139A1

T.(-).0139A1

Gudgeon pin fitting tool handle

(-).0139B

T.(-).0139B

Gudgeon pin fitting tool guide

end
(-).0139K

T.(-).0139K
 Gudgeon pin fitting tool Piston
locater
(-).0139L

T.(-).0139L

Plastigauge

Number 5 main bearing seals

fitting tool
(-).0153 A1 supplied with shims A2

T.(-).0153A1
Technical Department

IKCO Export after sales services department Engine Ref. No :1303R00202721/1

Technical description

Engine
The XU7 JP is a four-cylinder, in-line engine mounted
transversely at the front of the car, with two valves per
cylinder operated by a single overhead cam. The
cylinder block is of a light alloy with a cast iron
crankshaft incorporating eight balancing masses the
connecting rods are fitted with extra-flat pistons. The
timing is driven by a notched belt of high heat resistant
materials. The accessories are driven by a single
multiple vee-section belt with constant pressure being
supplied by an automatic tensioner.
The engine is equipped with a Magneti Marelli 8p fuel
injection system with the injection manifold being part of
the air inlet manifold.
XU7JPK - Sagem SL96
W72D001 XU7JPL3 - Sagem S2000

Cylinder Block
The cylinder block is cast in aluminium alloy, and the
bores have replaceable cast-iron liners that are located
from the top of the cylinder block. Sealing ‘O’ rings are
fitted to the base of each liner, to prevent the escape of
coolant into the sump.

W72D002
20 Technical description

Pistons
The pistons are made of light alloy and have grooves
for two compression rings and one scraper ring.
The top compression ring has a chromed radius, the
second compression ring has an oil-scraper function.
The scraper ring incorporates an expander.

W72D003

Connection rods
The connecting rods rotate on horizontally-split bearing
shells at their big-ends, these bearing shells are
replaceable. The pistons are attached to the connecting
rods by gudgeon pins. The gudgeon pins are an
interference fit in the connecting rod small-end eyes.

W72D004

Crankshaft assembly
The crankshaft is made of cast iron and has eight
incorporated balancing masses. The crankshaft runs in
five main bearings with thrust washers fitted to number
two main bearing cap to control crankshaft endfloat.
The crankshaft rotates on horizontally-split bearing
shells at main bearings, these bearing shells are
replaceable.

W72D005
 Technical description 21

Cylinder head and camshaft

The camshaft is driven by a toothed timing belt, and
operates eight valves via followers located beneath
each cam lobe. The valve clearances are adjusted by
shims positioned between the followers and the tip of
the valve stem. The camshaft runs in bearing caps
which are bolted to the top of the cylinder head. The
inlet and exhaust valves are each closed by coil
springs, and operate in guides pressed into the cylinder
head. The cylinder head gasket is asbestos free.

W72D006

Lubrication
Lubrication is by means of an oil pump which is driven
via a chain and sprocket from the crankshaft right-hand
end. It draws oil through a strainer located in the sump
and forces it through an externally-mounted filter into
the galleries of the cylinder block. From there, the oil is
distributed to the crankshaft main bearings and
camshaft. The big-end bearings are supplied with oil via
internal drillings in the crankshaft, the camshaft
bearings also receive a pressurised supply. The
camshaft lobes and valves are lubricated by splash, as
are all other engine components.

W72D007
 Adjustment and replacement
Engine remove
To remove
Special tools
1 Sling Bar (-).0102D.
3 1 2 Lifting hooks (-).0102G.
3 Ball joint extractor (-).0709.
4 Mounting plugs for drive shaft seals (-).0317T&U.
2
5 (-).0606 AY Hub clamp.

5
4 W72R001

1 Support the vehicle in a lift and tie the bonnet in

5 the upright position.
2 Drain the cooling system and remove top and
bottom radiator hoses (see book 4).
3 Drain the gearbox oil (see book 5).
4 If the engine is to be overhauled then drain
engine oil (see page 58).
5 Raise the vehicle and remove two nuts three bolts
and engine undertray.

W72R003
24 Adjustment and replacement

6 Remove two screws wheel arch liner to bumper,

one nut and three press fittings to wheel arch, one
screw to front framework and remove right-hand
wheel arch liner.

W72R072

7 Release the tension on the drive belt by using a

wrench in the hole at the pulley base and pulling
hard to the right, Insert a pin to lock the tensioner.
8 Remove the drive belt.

W72R162

9 On vehicles with air-conditioning, remove nut and

fixing plate and move aside air-conditioning pipes.
10 Remove electric connector and 4 bolts
air-conditioning compressor to engine and set
aside compressor (see book 11).
Note: it is not necessary to disconnect gas piping just
carefully suspend compressor from front framework.

W72R004
 Adjustment and replacement 25

11 Remove two bolts and torque reaction link.

12 Loosen two intermediate bearing retaining bolt
11 nuts and rotate bolts 90Þ so offset heads are
clear of bearing outer race.
11

12

12
W72R005

13 Remove the bolts from the anti-roll bar drop link to

the lower suspension arm.
14 Remove both front wheels.

13

W72R006

15 Remove ‘R’ clip and locking cap.

16 Using hub immobilising tool (-).060AY remove
driveshaft nut.
16 Note: Never apply brakes in order to loosen this nut as
damage may occur to the brake disc retaining bolts.

16 15
W72R007
26 Adjustment and replacement

17 Disconnect the lower suspension arms from the

hub carriers using (-).0709 ball joint extractor.
19 18 Remove bolts front lower wheel arch liners to front
framework so they can be pulled back for access.
19 Gently pull the hub carriers to pull the drive shafts
from the differential housing, and remove
driveshafts (see book 5).

17

W72R008

20 Remove two nuts exhaust front pipe to manifold

and two nuts and clamp front pipe to intermediate
pipe (see book 4).

W72R009

21 Remove the heat shield from the speedometer

drive housing.
22 Remove the retaining pin and withdraw the
22 speedometer cable.
23 Remove the tachometer electrical connector.

21

22

W72R010
 Adjustment and replacement 27

24 Release the clutch cable from the clips on the

24 wheel arch liner and air-conditioning pipes.
25 Remove the engine subframe (see book 6).

24

W72R011

26 Lower the vehicle and disconnect the engine

harness from the engine management ECU.
27 Release two clips and remove air intake pipe.
28 Disconnect and remove the battery and battery
fixing tray. (see book 11)
28

27

26 W72R012

29 Disconnect the Engine harness from the main

harness connectors and the battery plus unit.
30 Remove bolt and negative cable attachment from
29 battery tray fixing bracket.
29
29

30
W72R013
28 Adjustment and replacement

31 Release two clips and remove heater matrix

hoses from the engine compartment bulk head.

31

31
W72R014

32 Disconnect gear linkage rods from gearbox.

32

32
32

W72R015

33 Release the inner cable from the gearbox

mounting bracket.
34 Release the outer cable from the clutch release
33 lever.

34

W72R016
 Adjustment and replacement 29

35 Release clips and remove pipes from the upper

timing belt cover.

35

W72R017

36 Remove clip and disengage cable from throttle

36 body.
37 Disconnect the braking system servo vacuum
hose and MAP sensor hose from the inlet
manifold.
38 Depressurise the fuel system and disconnect feed
and return hoses (for procedure and precautions
see fuel book 3).

37
37

W72R018

39 Drain the power steering hydraulic fluid

(see book 6a).
40 Release clip and remove top hose to PAS pump.
41 Remove pipe from PAS pump and remove nut
and release pipe from PAS pump bracket.
41 42 Release PAS pump pipe from clips on engine
block.
41 43 Position the sling bar (-).0102 D and lifting hooks
(-).0102 G into the lifting eye located either side of
the cylinder head.
44 Attach a hoist to the sling bar and take up any
40 slack.

W72R019
30 Adjustment and replacement

45 Remove the nut from left-hand engine mounting

and recover the washer.
45 46 Remove two nuts and left-hand engine mount.
47 Remove transmission mounting shaft and washer.

47
46 46

W72R020

48 Remove two screws and mounting bracket.

48
49 Remove 3 bolts, mounting support bracket and
bridge piece.
49
50 Remove the mounting buffer.
49
51 Remove four nuts and right-hand engine mount.
52 Carefully lower the engine from the car.
49

50

51

W72R021

To fit
1 Refit is a reverse of the removal procedure,
though be aware of the following:
2 That no cables or hoses get trapped or pinched.
3 Inspect driveshafts and seals for wear, replace if
damaged.
4 Refill gearbox oil (see book 5).
5 Refill and bleed coolant system (see book 4).
 Adjustment and replacement 31

Drive belt and tensioner

To remove
1 Secure vehicle in a lift turn the steering to full right
lock and raise the vehicle.
2 Remove two screws wheel arch liner to bumper,
one nut and three press fittings to wheel arch, one
screw to front framework and remove right-hand
wheel arch liner.

W72R072

3 Release the tension on the drive belt by using a

wrench in the hole of the pulley base and pulling it
hard to the right. Insert a pin to lock the tensioner.

W72R162

4 Remove the drive belt.

5 Remove two bolts and belt tensioner from engine.

W72R163
32 Adjustment and replacement

To fit
1 Refit is a reverse of the remove procedure.

W72R163

Dipstick tube remove

3
1 Remove the dipstick from the tube.
2 Remove one bolt dipstick tube to cylinder head.
3 Withdraw the tube from its hole in the engine
block.
2 4 Refit is a reverse of the remove process, apply a
suitable locktite product to the bottom of the tube
where it enters the engine and tighten the bolt to
20Nm.

W72R160
 Adjustment and replacement 33

Cylinder head cover remove

To remove
1 Release clip and remove air cleaner to throttle
housing pipe. Release two clips, two screws and
remove filter cover.
1 1 1
2 Remove the air filter element

1
W72R023

3 Remove three pipes from cylinder head cover.

4 Release and move two fuel pipes aside.

W72R024

5 Release clips on cover and induction pipe.

5 6 6 Remove nut from ignition coil bracket and remove
induction pipe.

W72R025
34 Adjustment and replacement

7 Remove ten bolts in the sequence shown and

remove cylinder head cover/air cleaner assembly.
8 Collect the rubber seal.

9 5 1 4 8

10 6 2 3 7

W72R035

To fit
Before refit:
- Inspect the rubber seal and replace if necessary.
- Replace air filter if it shows any signs of wear or
damage.
1 Refit is a reverse of the removal process, tighten
bolts to cylinder head cover in the sequence
shown, tighten to 10Nm.
 Adjustment and replacement 35

Cylinder head remove

To remove
Special tools
1 Liner retaining clamp (-).0132 A1Z.
2 Bolt M11x150x60 (-).0153 J.
3 3 Camshaft gear setting rod (-).0153R.
1 4 Levers (-).0149.
5 Lifting hook (-).0102G.

4 5
W72R026

1 Disconnect the battery negative terminal.

2 Drain the engine cooling system and remove
cooling hose from thermostat (see book 4).
3 Remove two bolts exhaust front pipe to exhaust
manifold (see book 4).

3
3

W72R032

4 Remove bolt from engine to subframe mounting.

5 Remove the cylinder head cover (see page 33).

W72R027
36 Adjustment and replacement

6 Remove two screws and mounting bracket.

6
7 Remove 3 bolts, mounting support bracket and
7 bridge piece.
8 Remove the mounting buffer.
7
9 Remove nut from right-hand engine mount.

W72R028

10 Remove two bolts at the base of the cover and

remove cover.

10

W72R029

11 Connect a hoist to engine lifting eye and carefully

raise the engine.
12 Remove two bolts right-hand engine mounting to
cylinder head, then carefully lower vehicle back to
mounting.

12
W72R030
 Adjustment and replacement 37

13 Remove drive belt covers, and lock the camshaft

and crankshaft pulley. Remove the drive belt
(see page 50).
14 Remove the inlet manifold (see fuel book 3).

13

W72R031

15 Remove high tension leads from the coil and

spark plugs and the electrical connector from the
coil.
17 16 16 Remove 4 screws and coil from cylinder head.
17 Remove two bolts and HT lead fixing bracket.

15

W72R033

18 Remove bolt engine oil dipstick to cylinder head.

18

W72R034
38 Adjustment and replacement

19 Following the sequence shown progressively

loosen ten cylinder head bolts by half a turn a
time until bolts can be removed by hand.
20 Collect all washers and spacer.
Note: The position of the spacer for refitting.
2 6 10 7 3

1 5 9 8 4

W72R036

21 Displace the seal between cylinder head and

block by rocking the cylinder head using (-).0149
levers located in the bolt holes.
Warning: Be careful when lifting the cylinder not to
disturb the liners as coolant may pass through to the
sump and the liner bottom seals may get damaged.
22 Remove the cylinder head and collect the gasket
and locating dowels.

W72R037

23 Clean the joint faces with a descaling product,

and hold liners securely using (-).0132 A1Z
retaining clamps and (-).0153 J fixing bolts.
23

23

W72R038
 Adjustment and replacement 39

24 Remove two long bolts and washers from heat

24 shield/gasket assembly. Collect spacers.
25 25 Remove two bolts from both ends of the lower
24 heat shield and withdraw heat shield.

25 25
W72R043

26 Carefully lift upper heat shield gasket and remove

four upper nuts fixing manifold to cylinder head.

26
W72R044
40 Adjustment and replacement

Cylinder head refit

To fit
Before refit:
2
- Check the mating surfaces on the cylinder head
and block for pits and scratches and distortion,
skim the surface if required.
- Clean all bolt holes with a tap.
2 1 Remove piston liner retaining clamps.
2 Fit locating dowels and cylinder head gasket.
2 Note: The projecting tongue of the gasket goes to the
clutch end.

W72R039

3 Refit exhaust heatshield, gasket and manifold.

4 Check the camshaft and crankshaft are still
locked and position the cylinder head to the
locating dowels on the block.
5 Lubricate the cams and cam followers.
9 5 1 4 8 6 Apply grease to the cylinder head bolts and
position in cylinder head.
Note: Refit the spacer on the bolt noted from removal.
7 Following the sequence shown:
- Pre-tighten bolts to 60Nm
10 6 2 3 7 - Loosen completely.
- Tighten to 20Nm.
- Tighten a further 300Þ using a FACOM D360 type
tool.
W72R040

8 Connect a hoist to engine lifting eye and carefully

raise the engine.
9 Refit two bolts right-hand engine mounting to
cylinder head, tighten to 45Nm and lower the
vehicle back to the rubber mounting.

9 W72R041
 Adjustment and replacement 41

10 Refit nut to right-hand engine mount,.Tighten to

13 45Nm.
11 Refit the mounting buffer, tighten to 45Nm.
12
12 Refit mounting support bracket and bridge piece
12 and 3 bolts, tighten to 45Nm.
13 Refit mounting bracket and two screws, tighten to
20Nm.

11

10

W72R042

14 Position engine oil dipstick to cylinder head and

refit bolt.
15 15 Position HT lead fixing bracket and refit two bolts.
16
16 Position coil to cylinder head and refit four
screws.
17 Refit high tension leads and electrical connector
to coil.

17

W72R045

18 Refit the inlet manifold (see fuel book 3).

19 Refit drivebelt, remove locks from the camshaft
and crankshaft and refit lower drive belt covers.

19

W72R046
42 Adjustment and replacement

20 Position top drive belt cover and refit two screws.

20

W72R047

21 Refit the cylinder head cover (see page 33).

22 Refit bolt engine to subframe torque reaction link.

22

W72R048

23 Refit two bolts exhaust front pipe to exhaust

manifold.
24 Refil the engine cooling system (see book 4).
25 Connect the battery negative terminal.
26 Input security code to audio unit.

23

23

W72R049
 Adjustment and replacement 43

Camshaft and followers remove

To remove
1 Special tools
1 Camshaft gear stop (-).0132 Y
2 Camshaft oil seal fitting drift (-).0132 T.
2

W72R050

1 Disconnect the battery negative terminal.

2 Remove the cylinder head cover (see page 33).
5 3 Remove the camshaft sprocket (see page 47).
4 Remove high tension leads and electrical
connector from coil.
5 Remove 4 screws and coil from cylinder head.

W72R051

6 Remove the bolt and sealing washer from the

thermostat housing.

W72R052
44 Adjustment and replacement

7 Remove the oil lubrication rail from the camshaft

bearing caps.
8 Progressively loosen the bearing cap nuts one
7 turn at a time until the bolts can be easily
removed.
8 Note: The correct fitted orientation and location of each
bearing cap for refit, the crankshaft should be in timing
position.
9 Remove the camshaft and oil seal assembly.

W72R053

10 Remove the cam followers and shims from the

cylinder head.
Important: Note where each follower has come from
for refit.

10

W72R054

To fit
Before refit:
2 - Examine the camshaft, followers and bearing
surfaces for signs of wear or scoring, replace if
required.
1 Refit each shim to the top of its original valve
1
stem.
2 Lightly oil the cam follower bores and replace
each follower to its original bore.

W72R055
 Adjustment and replacement 45

3 Lightly oil the camshaft bearings and lobes then

refit camshaft to cylinder head.
4 Temporarily refit the sprocket and lock the
7 camshaft with locking pin.
5 Refit the bearing caps back to there original
6 position noted on removal.
Note: Apply sealant to the mating face of bearing cap
one were it meets the thermostat housing.
6 Replace the bearing cap spacers and nuts and
progressively tighten one turn at a time until
bearing caps touch the cylinder head face, then
tighten to 15Nm.
7 Replace oil lubrication rail, check the ‘O’ rings for
wear, replace if required.

W72R056

8 Check the valve clearances and adjust if required

(see page 46).
9 Refit the upper retaining bolt to the thermostat
9 housing, tighten to 15Nm.

W72R057

10 Refit the coil, high tension leads, and electrical

connector.
11 Remove the camshaft sprocket and fit new
10
camshaft seal (see page 47).
12 Refit camshaft sprocket (see page47).
13 Refit drive belt and remove all camshaft and
crankshaft locking tools.
14 Refit drivebelt top cover and cylinder head cover
(see page 50).
15 Connect the battery negative terminal.
10 16 Input security code to audio unit.

W72R058
46 Adjustment and replacement

Valve clearance checking and adjusting

Before checking:
- The engine must be cold minimum cooling time
2 hours.
1 Remove the cylinder head cover (see page 33).
2 Remove the ignition coil (see book 11).
3 Turn the crankshaft until the inlet valve of cylinder 1
(gearbox end) is fully closed.
4 Measure and note the distance between the cam
and the follower.
5 Progressively rotate the cam and repeat the
measurement on the other seven valves.

W72R059

6 The measurements for H should be as follows:

- Inlet valves 0.20Nm
- Exhaust valves 0.40Nm
7 - Tolerance ±0.05Nm
If the measurements are incorrect then:
7 Remove camshaft (see page 43).
8 Remove followers and adjustment shims.
H

W72R060

9 Measure the thickness of the adjustment shims E.

10 Determine the thickness of the replacement shims
using the example below:
Inlet Exhaust A
Operating 0.20mm 0.40mm 0.20mm
clearance
Clearance 0.10mm 0.55mm 0.45mm
measured
Difference -0.10mm +0.15mm +0.25mm
E 2.35mm 3.10mm 2.25mm
Shims to fit 2.25mm 3.25mm 2.5mm
Clearance 0.2mm 0.40mm 0.20mm
obtained
Note: If there has been any previous work on the cylinder
9 E head adjustment shims of 2.25mm will have been fitted.
See column A for example of calculating new shims.
W72R061 11 Refit as described in appropriate sections.
 Adjustment and replacement 47

Camshaft sprocket and oil seal replace

To remove
1 Special tools
1 Camshaft gear stop (-).0132 Y
2 Camshaft oil seal fitting drift (-).0132 T.
3 Crankshaft setting rod (-).0153G

W72R062

1 Remove the timing belt upper and middle covers

(see page 50).
2 Rotate the crankshaft pulley until the timing hole
in the camshaft sprocket is aligned with its
corresponding hole in the cylinder head.
Note: that the holes are aligned when the sprocket hole
2 is in the 8 ‘O’ clock position. Insert gear stop
(-).132Y into camshaft and setting rod (-).153G into
crankshaft.
The crankshaft and camshaft are now locked in
position, preventing unnecessary rotation.

W72R063

3 Loosen the timing belt tensioner pulley retaining

bolt. Pivot the pulley clockwise using a square
section key and tighten the retaining bolt.
4 Remove the timing belt from the camshaft
sprocket.

W72R064
48 Adjustment and replacement

5 Remove the bolt and camshaft sprocket.

6 Remove camshaft oil seal.
5
6

W72R065

To fit
Before refit:
- Check the sprocket and oil seal for signs of wear
or damage, replace if necessary.
1
- Lightly oil the lips of the seal before refit.
1 Refit the camshaft oil seal using (-).0132 T fitting
drift.

W72R066

2 Position the sprocket using gear stop (-).132Y and

2 refit bolt, tighten to 35Nm.
3 Further refitting is a reverse of the remove
procedure.

W72R067
 Adjustment and replacement 49

Valve remove
To remove
6 1 Remove the cylinder head (see page 35).
4 2 Remove the camshaft, followers and shims (see
page 43).
5 3 Compress each valve spring using a Facom U13L
type universal lifter.
4 Remove the split collets and release the tool.
5 Remove the spring retainer, spring and spring
seat.
5
6 Remove the valve stem oil seals.
7 Remove the valves from the bottom of the
cylinder head.
5 Note: Store each valve with its corresponding springs,
spring seats, retaining clips, followers e.t.c.
W72R068

To fit
Before refit:
- Examine each valve for bending, burning, pitting,
cracking and general wear.
- Check the springs for signs of distortion and
discolouration.
- Fit new valve stem oil seals as matter of course.
- Oil each valve stem and cam follower before refit.
1 Measure the valve stem width using a micrometer,
replace valve if any faults are detected.

W72R069

2 Replace each valve and grind into seats following

steps below:
- Place head upside down on a bench
- Apply a small amount of fine grinding paste to the
seat face.
- Attach a suction grinding tool to the valve head.
- With a semi-rotary action grind the valve to the head.
- Work until a smooth unbroken ring of light grey matt
finish is achieved.
- Clean all traces of grinding paste from the valve and
valve seat.
3 The remaining refit is a reverse of the remove
procedure.

W72R070
50 Adjustment and replacement

Timing belt and covers remove

To remove
Special Tools
1 Camshaft gear setting rod (-).0132R.
2 Crankshaft setting rod (-).0153G.
3 Flywheel stop. 9765.54.
4 Belt tension measuring equipment seem c.
Trionic type 87.
4 5 5 Crankshaft pulley extractor (-).0174.

1 3 2 W72R071

1 Drain the cooling system (see cooling book 4).

2 Raise vehicle and support securely and remove
front right-hand road wheel.
3 Remove wheel arch liner.
Note: Radiator bottom hose is fixed to liner with two
plastic ties.
4 Remove ancillary drive belt.

W72R072

5 Release clips and remove pipes from the upper

timing belt cover.
6 Remove two bolts at the base of the cover and
remove cover.

6
W72R073
 Adjustment and replacement 51

7 Rotate the crankshaft pulley until the timing hole

in the camshaft sprocket is aligned with its
corresponding hole in the cylinder head.
Note: that the holes are aligned when the sprocket hole
is in the 8 ‘O’ clock position. Insert setting rod
(-).0132R into camshaft and setting rod (-).0153G into
7 crankshaft.
The crankshaft and camshaft are now locked in
position, preventing unnecessary rotation.

W72R074

8 Remove clutch housing bottom closing plate.

9 Lock flywheel with stop 9765.54 and remove
crankshaft setting rod.
8

W72R075

10 Remove centre cover. Remove two upper screws,

move cover up to release from locating screws
which retains lower cover.

10

W72R076
52 Adjustment and replacement

11 Remove crankshaft pulley using pulley extractor

(-).0174.

11

W72R077

12 Remove lower cover. If auxiliary equipment, such

as air conditioning is fitted, it may be necessary to
remove the auxiliary drivebelt tensioner. This will
assist the removal of the lower cover.
12

W72R078

13 Loosen the timing belt tensioner pulley retaining

bolt. Pivot the pulley clockwise using a square
section key and tighten the retaining bolt.

13

W72R079
 Adjustment and replacement 53

14 Mark timing belt for refitting.

14 15 Remove belt.

15

W72R080

To fit
1 Ensure that the camshaft setting tool is in
position.
2 Temporarily refit crankshaft and insert setting tool
to ensure crankshaft is correctly positioned. If
correct remove setting tool and remove crankshaft
pulley.

W72R081

Note: Check timing belt for wear or damage. Renew if

3 there is the slightest doubt about its condition or if the
vehicle has covered more than 60,000 Km with the
existing belt, renew as a matter of course.
3 Fit timing belt into position ensuring that any
arrows are positioned in the direction of rotation.
If existing belt is being reused, line up marks.
Ensure the front run is taut and any slack is on
the tensioner pulley side.
3

W72R082
54 Adjustment and replacement

4 Loosen the tensioner pulley retaining bolt. Using

the square-section key, pivot the pulley
anti-clockwise to remove all free play from the
timing belt.

W72R083

5 Remove camshaft setting rod. The special belt

7 tension measuring equipment should be fitted to
the front run of the timing belt. The tensioner roller
should be adjusted so that the initial belt tension
is 30 ± 2 units.
6 Tighten the pulley retaining bolt to 20 Nm.
7 Refit the crankshaft pulley again, tightening
5 retaining bolt by hand only.
Rotate the crankshaft through at least two
complete rotations in a clockwise direction
(viewed from the right-hand end of the engine).
Do not at any time rotate the crankshaft anti-
clockwise. Both camshaft and crankshaft timing
holes should be aligned so that the locking pins
can be easily inserted. This indicates that the
7 valve timing is correct.
W72R084

8 The final belt tension on the front run of the belt

should be 44 ± 2 units. Readjust the tensioner
pulley position as required, then re-tighten the
retaining bolt to 20 Nm. Rotate the crankshaft
through a further two rotations clockwise, and re-
check the tension. Repeat this procedure as
necessary until the correct tension reading is
obtained after rotating the crankshaft.
Remove crankshaft pulley.

W72R085
 Adjustment and replacement 55

9 Refit lower cover.

W72R086

10 Refit crankshaft pulley. Tighten 120 Nm.

10

W72R087

11 Fit centre cover. Ensure bottom fixing is retained

by pushing down onto lower cover screws.
Tighten two upper bolts to 8 Nm.

11

W72R088
56 Adjustment and replacement

12 Refit upper cover. Tighten to 8 Nm. Refit pipes to

upper cover. Refit wheel arch liner.
Note: Fit new cable ties (bottom hose to wheel arch liner).

12
W72R089
 Adjustment and replacement 57

Timing belt tensioner - sprockets remove

Timing belt tensioner remove
1 Remove timing belt covers and lock timing gear
(see page 50).
2 Loosen the timing belt tensioner pulley retaining
bolt. Pivot the pulley clockwise using a square
section key to release belt tension and remove
retaining bolt and tensioner.
2
3 Refit is a reverse of the remove procedure,
Examine its mounting stud for signs of damage.
and make sure the timing belt is tighten to the
correct amount.

W72R090

Crankshaft sprocket remove

1 Remove timing belt covers and lock timing gear
and crankshaft (see page 50).
5 2 Remove clutch housing bottom closing plate and
lock flywheel with stop 9765.54 .
3 Loosen the timing belt tensioner pulley retaining
bolt. Pivot the pulley clockwise using a square
section key and tighten the retaining bolt.
4 Remove the timing belt off the crankshaft sprocket
and slide the sprocket from the crankshaft.
5 Retain the woodruff key for refitting.

4
W72R091

6 Refit is a reverse of the remove procedure,

examine the crankshaft oil seal for signs of
damage, replace if necessary (see page 66).
7 Make sure the timing belt is tightened to the
correct amount (see page 57).
58 Adjustment and replacement

Engine oil and filter renew

Engine oil remove
1 Place car securely on a lift and raise the vehicle.
2 Remove three bolts, two nuts and remove engine
undertray.
3 Remove the engine oil drain plug and allow the oil
to drain into a suitable container.
4 Recover the sealing washer.
Note: It is recommended that you drain the engine oil
while still warm, care should be taken to not burn
yourself with the oil or the exhaust front pipe.

3
4 W72R092

Oil filter remove

4 Drain the engine oil as described above
1 Remove the oil filter using a suitable removal tool
if required.
2 Drain any remaining oil into a suitable container.
3 Clean thoroughly the filter sealing area of the
engine.
4 lightly apply clean engine oil to the sealing ring of
the new oil filter and screw it into position.
Note: It is important to only tighten new filter by hand,
do not over tighten with a tool.

1 W72R093

Oil refilling
6 1 Replace oil filter and refit drain plug and new
sealing washer, tighten to 35Nm.
2 Position engine undertray and replace three
screws and two nuts.
3 3 Lower the vehicle and remove the oil filler cap
and the engine oil dipstick.
4 Half fill the engine with the recommended quantity
and type of oil, then wait a short time for the oil to
reach the sump.
5 Add oil in small quantities checking occasionally
the level on the dipstick.
6 When full replace the filler cap and run the engine
for a time and check around the drain plug and
filter for any leaks. Stop the engine, check the oil
W72R094 level and top up if required.
 Adjustment and replacement 59

Oil pressure check

Special tools
4 Pressure testing kit (-).1503. ZY
1 Pressure gauge.
2 Flexible hose.
3 3 Union.
4 Pin.

1 2 W72R095

Oil pressure is checked with the engine hot after

3 checking the oil level.
1 Remove the connector to the oil pressure switch.
2 Remove the pressure switch from the engine and
2 replace it with the union from the kit (-).1503. ZY.
3 Connect the pressure gauge and flexible hose
and read the pressure. The minimum oil pressure
at 4000rpm and 80 °C must be 5.3bar, If below
then proceed with the remaining steps.

W72R096

4 Remove the pressure gauge and union.

5 Refit a new washer and the oil pressure sensor,
tighten to 30Nm.
6 Replace the electrical connector.

W76R097
60 Adjustment and replacement

Sump remove
To remove
4
1 Remove the battery negative terminal.
2 On vehicles with air-conditioning remove the drive
belt (see page 31).
3 Put the vehicle on a lift and raise.
4 Remove three bolts, two nuts and engine
undertray.
5 Remove the oil drain plug and washer and allow
the engine oil to drain into a suitable container.
Refit the drain plug once the sump is empty,
tighten to 35Nm.
Warning: The engine oil and exhaust downpipe could
be extremely hot.
Note: It is recommended that the oil filter is also
changed during this operation (see page 58).
W72R098

5 On vehicles with air-conditioning, remove nut and

fixing plate and move aside air-conditioning pipes.
6 Remove electric connector and 4 bolts
air-conditioning compressor to engine and set
aside compressor (see book 11).
Note: it is not necessary to disconnect gas piping just
carefully suspend compressor from front framework.

W72R099

7 Progressively slacken and then remove the sump

retaining bolts.
Note: The retaining bolts are different lengths, make a
record of their locations for refit.
8 Remove the sump, a small tap might be required
to break the seal to the engine block, collect the
locating dowel for refit.
8

7
8
7
W72R100
 Adjustment and replacement 61

To fit
Before refit:
1
- Clean the sump thoroughly.
- Remove all traces of sealant from the sump and
engine mating faces and wipe dry with a cloth.
- Check the gasket for signs of damage, replace if
required.
1 Apply a seam of sealant to the sump as shown in
the illustration.

W72R101

2 Refit the locating dowel into the engine block.

3 Position the sump to the engine and refit the
retaining bolts to their positions noted on removal,
tighten to 16Nm.
4 Position the air-conditioning compressor and refit
four bolts and electrical connector.
5 Position air-conditioning pipes and fixing plate and
2 refit nut.

3
3
3
W72R102

6 Position engine undertray and refit three bolts and

6 two nuts.
7 Lower the car and refit the drive belt (see page
31).
8 Fill the engine with the specified type and quantity
of oil (see page 6).
9 Connect the battery negative terminal and reset
the audio security code.
10 Run the vehicle for a time and check the sump for
signs of leakage.

W72R103
62 Adjustment and replacement

Oil pump and deflector remove

To remove
1 Remove the sump (see page 60).
2 2 Remove two screws and sprocket cover from oil
pump.
3 Remove three retaining bolts and remove oil
4 pump from cylinder block.
4 Remove the spacer plate.
Note: Examine the oil pump sprocket, chain and drive
3 sprocket for signs of wear or damage, replace if
required. To replace the drive sprocket proceed as
follows.
2

3
W72R104

5 Remove the timing belt crankshaft sprocket (see

page 57).
7 6 Remove six bolts and oil seal support plate from
6 the engine block collect the location dowels for
7 refit.
Note: The retaining bolts are different lengths. make a
record of their locations for refit.
7 Remove the chain from the sprocket and slide the
drive sprocket and sealing ring from the
crankshaft and collect the woodruff key.

6
6
W72R105

Oil deflector remove

1 Pull the oil deflector from feed pipe in the engine
block.
1 2 To refit examine the deflector for any signs of
damage or blockage, replace if necessary. Apply
a suitable locktite product to the inlet tube and
push back into the feed pipe on the engine.
2

W72R159
 Adjustment and replacement 63

To fit
Before refit:
- Thoroughly clean and dry all parts.
- Clean the oil strainer with a suitable solution and
examine it for signs of clogging or splitting.
1 Refit the woodruff key, lubricate the sealing ring
and slide it, together with the drive sprocket onto
the crankshaft.
2 Place the driving chain onto the sprocket.
2

1
W72R106

3 Apply sealant to the mating face of the engine

block and refit the location dowels.
3 4 Position oil support plate and refit bolts to
4 locations noted on remove, tighten to 15Nm.
2 5 Refit the timing belt sprocket and timing belt (see
page 57).

4
4
W72R107

6 Replace the spacer plate.

7 Position the oil pump and refit three retaining
8 bolts, tighten to 16Nm.
8 Position sprocket cover to oil pump and replace
two screws.
6 9 Refit the sump (see page 60).

7
W72R108
64 Adjustment and replacement

Flywheel remove
To remove
Special tools
1 Flywheel stop 9765.54.

W72R109

1 Remove the gearbox and clutch assembly (see

gearbox book 5).
2 Lock the flywheel into position using 9765.54
flywheel stop.

W72R110

3 Progressively loosen and remove eight bolts from

the flywheel.
4 4 Remove the flywheel from the crankshaft, and
collect the locating dowel for refit.

3
4

W72R111
 Adjustment and replacement 65

To fit
2 Before refit.
- Clean and dry all parts thoroughly.
- Inspect the flywheel for signs of scoring on the
clutch face and damage to the ring gear teeth.
Replace if required.
1 Refit the locating dowel to the crankshaft.
2 Position the flywheel on the crankshaft and hold
in position using 9765.54 flywheel stop.

W72R112

3 Using new bolts, coat with a locking compound

2 and refit flywheel to crankshaft, tighten to 50Nm in
7 the sequence shown.
5
4 4 Refit the clutch assembly and gearbox (see
gearbox book 5).
3
6
8
1

W72R113
66 Adjustment and replacement

Crankshaft oil seal remove

Special tools
1 Right-hand crankshaft oil seal fitting drift.
(-).0153D
2 Left-hand crankshaft oil seal fitting drift. (-).0153B.

W72R114

Right-hand oil seal

2 1 Remove the crankshaft sprocket (see page 57).
2 Note the correct depth of the fitted seal for
3 refitting.
3 Carefully lever out the seal using a flat bladed
+ 0.2 screw driver.
0.4 - 0.2 mm 4 Clean the sealing housing thoroughly.
5 Oil the seal mating face and locate to the housing.
6 Refit the oil seal to the depth measured before
removal. Refit seal using (-).0153D fitting drift.
7 Refit the crankshaft sprocket (see page 57).

W72R115

Left-hand oil seal

1 Remove the flywheel (see page 64).
2 Note the correct depth of the fitted seal for
refitting.
3 Carefully lever out the seal using a flat bladed
screw driver.
3 4 Clean the sealing housing thoroughly.
5 Oil the seal mating face and locate to the housing.
6 Refit the oil seal to the depth measured before
removal. Refit seal using (-).0153B fitting drift.
7 Refit the flywheel (see page 64).

W72R116
 Adjustment and replacement 67

Engine/gearbox mountings remove

Right-hand mounting
1 Special tools
1 Crossbeam and adjusting screw.(-).0911.A1.
2 Crossbeam support (-).0911 A2.

W72R117

1 Hold the engine in position with cross beam

2 (-).0911 A1 fitted with supports (-).0911 A2.
3 2 Remove two screws and mounting bracket.
3 Remove 3 bolts, mounting support bracket and
3 bridge piece.
4 Remove the mounting buffer.

W72R118

5 Remove four nuts from right-hand engine mount.

6 Remove the rubber buffer plate.
5
7 Unscrew the mounting rubber from the body.
5
To fit
Before refit examine all the mounting rubbers carefully
for signs of damage or hardening, replace if required.
1 Refit is a reverse of the remove procedure but
observe the following torque settings.
- Mounting rubber 40Nm.
- Four nuts right-hand engine mount 45Nm.
- Mounting buffer 45Nm.
6 - Three bolts mounting support bracket 45Nm.
7
W72R119
68 Adjustment and replacement

Left-hand mounting
1 Disconnect and remove the battery and it’s
supporting tray (see book 11).
2 2 Hold the engine in position with cross beam
(-).0911 A1 fitted with supports (-).0911 A2.

W72R120

3 Remove the nut from left-hand engine mounting

and recover the washer.
3 4 Remove two nuts and left-hand gearbox mount.
5 Remove gearbox mounting shaft and washer.

5 To fit
4
4 Before refit examine the mounting rubber carefully for
signs of damage or hardening, replace if required.
1 Refit is a reverse of the remove procedure but
observe the following torque settings.
- Gearbox shaft 50Nm.
- Gearbox mounting nuts 23Nm.
- Mounting shaft nut 65Nm.

W72R121

Torque reaction link remove.

1 Remove right-hand drive shaft (see book 5).
3 2 Remove two bolts and torque reaction link.
3 Remove four bolts and torque reaction link
3 bracket.
4 Refit is a reverse of the remove procedure,
tighten the following bolts to torque settings
shown.
3 - Bracket bolts to engine ??Nm.
3
- Torque reaction link to body ??Nm.
- Torque reaction link to bracket ??Nm.
2
2
W72R158
 Adjustment and replacement 69

Engine overhaul
A full engine overhaul requires the engine to be
6 8 completely free of all external components, the following
4
steps show the items to be removed. Refer to appropriate
7 manuals for more information on the relevant operations.
1 Engine from the vehicle.
5 2 Gearbox from engine.
3 Alternator and belt tensioner.
4 Power steering pump and bracket.
5 Thermostat and its housing.
6 Inlet manifold.
7 Ignition coil, high tension leads and spark plugs.
8 Cylinder head.
9 Starter motor and engine harness.
3 10 9 2 10 Oil filter.
W72R122

11 Exhaust manifold.
12 12 Dipstick tube.
13 Intermediate bearing housing.
14 Heater matrix pipes and housing.

11
14

13

W72R123

15 Timing belt.
16 Crankshaft pulley.
17 Timing belt tensioner and sprockets.
18 Water pump.
19 Sump.
20 Oil pump.
17 21 Flywheel.
The engine is now in a condition to overhaul all the
internal components of the cylinder block. The following
pages will give you a detailed operation of the different
stages.
15

17 W72R124
70 Adjustment and replacement

Piston and connecting rod overhaul

Piston remove
4
1 Secure piston liners to engine block using
(-).0132 A1Z clamp plates.
2 Mark the bearing caps for reference for refitting.
3 Rotate the crankshaft to bring pistons 1 and 4 to
bottom dead centre.
5 4 Remove two nuts from piston 1 big end bearing
cap and remove cap.
5 Recover bearing half shell if not attached to cap.
6 Withdraw piston through the top of the engine
block.
7 Repeat steps for remaining three pistons.
Note: Record which piston is comes from which liner
for refit.
W72R125

Piston ring and gudgeon pin remove

Remove and refit text:
2 1 Remove the piston (see above).
2 Carefully expand the chromed radius ring and pull
3 from the top of the piston.
3 Carefully expand the taper ring and pull from the
top of the piston.
1 Note: Piston rings can break very easily. Once broken
the rough edges can be very sharp.
4 4 Expand and remove the scraper ring, this ring has
an expander.

W72R126

5 Place the piston face with its centre bore on the

tool (-).0139 L.
6 Fit guide pin tool (-).0139K to the gudgeon pin
and press from piston.
Note: Once the gudgeon pin has been removed the
piston has to be scraped.
6

W72R175
 Adjustment and replacement 71

Inspection
1 Examine each piston for cracks around the skirt
and gudgeon pin holes.
2 Check the piston for scoring and the crown for
holes or burning.
3 Clean all traces of carbon from the piston crown
using a wire brush.
4 Examine connection rods for signs of damage,
replace if required.
5 New piston rings should be used as a standard
measure.

Piston and gudgeon assembly

1 Fit piston one gudgeon pin to (-).0139K guide
end.
4 2 Loosly screw handle (-).0139B to the guide end.
3 Place Piston locater (-).0139L onto base
(-).0139A1.
3 4 4 Open the clamp and fully unscrew the holding
A1 pads.

1
W72R143

5 Position the centre bore side of the piston to the

5,7
piston locater and insert the guide end, gudgeon
pin and handle assembly to position the piston
correctly.
Important: When you position the piston onto the
6 locater the surface with the boss should be facing
6
upwards.
6 Pull down the handle and fit its locating pin and
tighten the holding pads when they contact the
piston.
7 Remove the gudgeon pin assembly from the
piston, making sure that it moves freely.
5

W72R144
72 Adjustment and replacement

8 Refit the big end bearing without shells to the

11 9 connecting rod and place it on base (-).0139A1.
9 Refit Gudgeon pin. guide end, handle assembly to
centralise the connecting rod.
10 Change the height and position of the adjuster to
line up the connection rod and piston correctly.
11 Allow a clearance of 0.1Nm between the adjuster
and the big end bearing.
12 Remove the gudgeon pin assembly.

8
10
W72R146

13 Arrange the connecting rods onto a suitable

electric heating element and place a scrap of tin
solder on each little end.
14 Heat the connecting rods to between 230Þ to
13 270ÞC so the solder melts.
Warning: The handling of the connection rod should be
undertaken with extreme caution as they are now very
13 hot.
13

13

W72R147

15 Oil the gudgeon pin and insert through the piston

in one smooth constant action.
16 Repeat the steps for the remaining three pistons.
15
Note: The success of the operation depends on this
being done quickly.

W72R148
 Adjustment and replacement 73

Piston ring refit

Piston rings are easier to fit if their matching piston
liners are removed (see page 79).
120 o 120 o 1 Refit the scraper ring.and position the gap of the
ring as shown.
3 2 Refit the taper ring as shown and position its gap
at 120Þ to the gap of the scraper ring.
2 3 Refit the chromed radius ring as shown and
1 position its gap at 120Þ in the other direction to
the gap of the scraper ring.
1 4 Lightly oil the piston and position ring clamp.

W72R127

5 Position piston assembly securely on a bench.

6 6 Position the piston into its corresponding liner so:
- The markings on the liner and the block coincide
(if linings have been removed).
7 - The arrows on the piston crown point towards the
timing gear.
7 Push the liner on to the piston until the ring clamp
is freed.
8 Repeat the procedures for the remaining three
pistons.

W72R128

Big end refit and running clearance check

Before refit:
- Use new bearing half shells for refit.
- Make sure the connection rod and bearing end
caps are clean.
- Start this procedure with piston one. Once
complete perform the procedure with the
remaining three pistons.
1 Press the bearing shells into their correct
positions on the connection rod and bearing cap
so that the tab engages with the recess.
2 Clean the parts to be measured making sure that
they are free from oil and dirt.
3 Place a strip of Plastigage (green) in the
lengthwise direction of the crankpin journal.
W72R129
74 Adjustment and replacement

4 Refit the bearing cap and tighten the two nuts to

40Nm.
Note: The crankshaft must remain completely still
during measurement.
5 Remove the bearing cap, the strip of plastigauge
4 should now be on the bearing cap or the crankpin
journal.

W72R130

6 Use the scale printed on the plastigauge

envelope. Measure the strip at its widest point
taking care not to touch it with your fingers.
7 Remove all traces of the plastigauge from the
crankpin and the bearing shells.

W72R131

8 lightly lubricate the crankpin journal and half

shells.
9 Position the big end bearing cap and refit nuts
and tighten to 40Nm.
10 Loosen the bolts and tighten again to 20Nm,
9 followed by a further 70Þ.
11 Repeat this procedure for the remaining three
pistons.

W72R132
 Adjustment and replacement 75

Crankshaft and main bearing overhaul

Main bearing remove
5 The main bearings are numbered one to five with
number one being at the flywheel end. Mark the
4 bearing caps for referral on refit.
4 1 Remove the oil seal support plate and oil pump
drive sprocket.
4 3 2 Remove big end bearing caps.
3 Remove two centre main bearing cap bolts and
4 4 washers from either side of the engine block.
4 4 Remove bolts from the Main bearing caps and
remove caps. Recover the lower bearing shells.
4 5 Remove the lower thrust washer halves from the
3 side of the number two bearing cap.

W72R133

6 Remove and discard the side sealing strips from

main bearing one.
6

W72R134

Crankshaft remove
1 Remove main bearing cap as described above.
2 2 Lift out the crankshaft and discard the oil seal.
3 Recover the upper bearing shells and the upper
thrustwasher halves from main bearing two.
3 Note: Keep the upper bearing shell with its matching
lower shell if they are going to be refitted.
3
3
3
3

W72R135
76 Adjustment and replacement

Crankshaft inspection
3 1 Thoroughly clean and dry the crankshaft.
2 Check for wear, scoring, pitting, and cracking
around the main and big end journals.
3 Using a micrometer, measure the main and big
end journals at a variety of different positions
around their circumference. If the distances vary
greatly then the journals will have to be ground
down or the crankshaft replaced.
4 Clean all oil holes with a suitable pipe cleaner.

W72R136

Main bearing running clearance check

Before refit:
- Use new bearing half shells for refit.
- Make sure the crankshaft and bearing end caps
are clean.
1 Press the bearing shells into their correct
positions on the engine block crankcase and main
bearing caps so that the tab engages with the
recess.
2 Clean the parts to be measured making sure that
they are free from oil and dirt.
3 Place a strip of Plastigage (green) in the
lengthwise direction of the crankshaft bearing
journals.

W72R149

4 Refit the main bearing caps and tighten the nuts

to 50Nm.
4 Note: The crankshaft must remain completely still
4 during measurement.
5 Remove the bearing caps, the strip of plastigauge
should now be on the bearing cap or the
crankshaft.

W72R150
 Adjustment and replacement 77

6 Use the scale printed on the plastigauge

envelope. Measure the strip at its widest point
taking care not to touch it with your fingers.
7 Remove all traces of the plastigauge from the
crankshaft and the bearing shells.

W72R151

Crankshaft refit
It is recommended that new bearing shells and thrust
bearings be fitted at this stage, recommended
2 thicknesses can be found in the technical data section.
1 Refit the upper bearing half shells and lightly
1 lubricate with oil.
2 Position the crankshaft.
3 3 Refit the two upper thrust half washers, the oil
grooved face towards the crankshaft.
3
3
3
3
W72R137

4 Fit new side seals to main bearing cap one.

5 Apply a coat of silicon sealing compound to the
6 6 4 Bearing cap surface shown.
6 Attach tool (-).0153 A1 fitted with shims A2, using
a bolt and washer.
6 7 Fit bearing cap one lower half shell and lubricate
4 shell and crankshaft.

6
5

W72R138
78 Adjustment and replacement

Warning: To avoid stretching the side seals, fit the

bearing cap as follows:
8 Insert the bearing cap into the housing at an
angle of 45Þ.
11
9 Straighten it and lower it into position.
10 Replace two bolts and tighten by hand.
11 Remove the fixing bolt and withdraw the tool
10 horizontally.

10

W72R139

12 Refit half bearing shell to main bearing cap

12 number two, lightly lubricate and refit cap to
13 engine.
14 13 Refit the two lower thrust half washers, the oil
grooved face towards the crankshaft.
14 14 Refit half shells to the remaining main bearing
caps, lightly lubricate and refit to engine following
14 16 the identification marks made on remove.
14 14 15 Refit remaining cap bolts and tighten all to 50Nm.
16 Refit Main bearing cap number three side
14 washers and bolts, tighten to 25Nm.
14 17 Check the protrusion of the side seals, the
16 measurement should be approximately 2Nm, cut
back if required.

W72R140

Checking crankshaft endfloat

1 Fit the dial gauge to the timing gear end of the
cylinder block and position gauge to the
crankshaft.
2 Push the crankshaft to one end and zero the dial.
3 Push the crankshaft in the other direction and
1 read the measurement.
4 Endfloat should read 0.07 to 0.27Nm.
5 If the measurement is too big then thrust half
washers need replaceing.
Note: All four thrust washers must be of the same
2,3
thickness, for recommended thicknesses see technical
data.
6 Check the crankshaft flows freely.
7 Fit new crankshaft oil seal (see page 66).
W72R141
 Adjustment and replacement 79

Cylinder liner overhaul

To remove
1 Remove pistons (see page 70).
2 Remove cylinder liner clamps.
4
3 Clearly identify the cylinder liner with its piston
number and orientation in the block.
4 Remove the cylinder liner from the top of the
engine block, a gentle tap from inside the engine
will help to remove the liner.
5 5 Remove the ‘O’ ring from the bottom of the liner
and discard.

W72R152

Inspection
1 Check each liner for signs of scuffing or scoring
and excessive wear around the top.
2 Measure the bore diameter at the top, middle and
3 2 bottom parrellel to the crankshaft axis.
3 Measure the bore diameter in the same three
areas but at 90Þ to the previous readings.
4 Compare the results with those in technical data
page ?, if there is a greater distance then the
liners will need replaceing.

W72R153

To fit
Before refit:
1 Thoroughly clean the liner and its mating surfaces
4 inside the engine.
2 Fit new ‘O’ rings and apply grease to the bottom
of the liner.
3 Position the liner to the engine block noting the
4 locations marked on remove.
2 4 Firmly push the liners into position, use a small
hammer and wooden block to help.
4 5 Lightly oil all exposed areas of the liner and check
liner protrusion.

W72R154
80 Adjustment and replacement

Cylinder liner protrusion

The liners have identification marks that will coincide
with the marks on the top of the piston crown. Always
make sure that liners and pistons always have the
same grades.
1 With the liners refitted position the plate (-).0132B
A-B-C with its flat face pointing upward.
2 2 Position the dial gauge (-).0132C onto the plate
and zero it on the liner.
3 Measure the distance in the three positions
shown, the difference must not exceed 0.02Nm.
Make further adjustments to the liner if the
1 measurement is wrong.

W72R155

4 Measure the distance between the liner and the

engine block at the three positions shown. The
4 difference between the measurements should not
exceed 0.02Nm. Make further adjustments to the
liner if the measurement is wrong.
5 Repeat the above procedures on the other three
cylinder liners.

W72R156

6 Check the difference in levels between joining

faces of the cylinder liners, this measurement
should not exceed 0.05Nm.
Note: With new liners this distance may be corrected
by lifting and turning the liner 180Þ.

W72R157
 Adjustment and replacement 81

Engine build up
After a full engine overhaul the engine needs to be
completely fitted of all external components, the following
steps show the items to be fitted. Refer to appropriate
manuals for more information on the relevant operations.
1 Flywheel.
2 Oil pump.
3 Sump.
5 4 Water pump.
5 Timing belt tensioner and sprockets.
6 Crankshaft pulley.
7 Timing belt.
7

5 W72R167

8 Heater matrix pipes and housing.

10 9 Intermediate bearing housing.
10 Dipstick tube.
11 Exhaust manifold.

11
8

W72R168

12 Oil filter.
18 16 14 13 Starter motor and engine harness.
15 14 Cylinder head.
15 Ignition coil, high tension leads and spark plugs.
16 Inlet manifold.
17 17 Thermostat and its housing.
18 Power steering pump and bracket.
19 Alternator and belt tensioner.
20 Gearbox to engine.
21 Engine to vehicle.

19 12 13 20
W72R169
82 Adjustment and replacement

Initial startup after overhaul

After a full overhaul the engine must be treated as new,
time has to be given to run in all new parts. Do not
operate the engine at full throttle or allow it to labour at
low engine speeds in any gear. It is recommended you
follow these guide lines for the first 800km and change
the engine oil after this time.
1 Remove the spark plugs.
2 Remove the electric connector from the ignition
coil.
3 Turn over the engine until the oil pressure warning
light goes out.
4 Replace the spark plugs and ignition coil electrical
connector.
5 Start the engine. and while idling check for oil and
water leaks.

6 When the engine reaches full temperature and

water starts to enter through the top hose, then
switch off the engine.
7 Check ignition timing, water and oil levels and
adjust accordingly.