DOHC Engine Cylinder Block
1 - cylinder block, 2 - front cylinder block cover, 3 - front crankshaft seal ring, 4 - front cylinder block cover gasket, 5 - oil pan, 6 - oil pan gasket, 7 - oil drain plug, 8 - plugs, 9 - rear cylinder block cover gasket, 10 - rear cylinder block cover, 11 - rear crankshaft seal ring, 12 - threaded plug
DOHC engine crank mechanism
1 - crankshaft, 2 - main bearing caps, 3 - main bearing shells, 4 - crankshaft thrust half rings, 5 - crankshaft position sensor ring gear, 6 - crankshaft rear sealing ring, 7 - engine flywheel for vehicles with manual transmission, 8 - engine flywheel for vehicles with automatic transmission, 9 - connecting rod shells, 10 - connecting rod cap, 11 - connecting rod, 12 - piston pin, 13 - piston, 14 - piston rings, 15 - crankshaft front sealing ring, 16 - woodruff key
Removal the DOHC engine oil pump
1 – chain tensioner, 2 – pump drive chain, 3 – pump sprocket mounting bolt, 4 – pump sprocket, 5 – oil pump, 6 – oil pump mounting bolt to cylinder block
Disassembly
1. Secure the engine to a suitable frame.
2. Drain the oil from the engine and remove the oil level indicator.
3. Using a suitable tool, unscrew the oil filter.
4. Unscrew the bolts securing the leading part of the clutch, and then remove the clutch disc.
5. Remove the flywheel.
6. Remove the generator and coolant pump drive V-belt, the generator and its holder.
7. Remove the crankshaft vibration damper using a suitable puller.
8. Remove the distributor cap and unscrew the spark plugs.
9. Remove the ignition distributor and unscrew the high-voltage wire holder.
10. Remove the cylinder head cover.
11. Remove the upper and lower covers of the cardan chain of the timing system.
12. Remove the oil pump cardan chain tensioner.
13. Unscrew the bolts securing the oil pump sprocket and remove it together with the chain.
14. Disconnect the upper guide of the cardan chain of the timing system.
15. Unscrew the two bolts securing the side guide of the cardan chain of the gas distribution system.
16. Remove the spring clamp securing the tensioner axle of the cardan timing chain.
17. Remove the axle of the tensioner of the cardan chain of the gas distribution system using the bolt M6x70 and a sleeve 15 mm long (see Fig. Installing the valve timing of a DOHC engine).
18. Remove the chain tensioner lever.
19. Remove the sprockets from the camshafts.
20. Remove the upper chain guide (up).
21. Remove the double sprocket from the crankshaft.
22. Remove the camshaft drive chain.
23. Remove the chain tensioner push rod.
24. Remove the two camshafts (cover designations: "R" – intake valve shaft, "L" – exhaust valve shaft, numbers "1" – "5" – bearing number, counting from the timing drive side).
25. Remove the hydraulic valve lifters and mark them so that during assembly they can be installed in the guides with which they interacted.
Caution: When removing the tappets from the guides, do not use magnets as they may cause the valve inside the tappet to malfunction.
26. Remove the rigid air bleed lines under the cylinder head cover.
27. Remove the cylinder head bolts by first unscrewing the three front M8 bolts, then the M11 bolts in the reverse order to how they were tightened (see Fig. DOHC Engine Cylinder Head Bolt Tightening Sequence), initially loosening them by half a turn.
28. Remove the oil pump mounting Torx socket bolts and remove the oil pump.
29. Unscrew the oil pressure sensor and the crankshaft position sensor.
30. Remove the oil pan after unscrewing the bolts that secure it.
31. Remove the oil pump oil receiver mesh filter and the oil pan partition (oil deflector).
32. Remove the front and rear crankshaft seal rings.
33. Check the markings on the main bearing caps, unscrew the bolts that secure them and remove the caps together with their liners.
34. Remove the crankshaft. Be careful not to damage the toothed pulse sensor that interacts with the crankshaft position sensor.
35. Remove the crankshaft thrust half ring from the middle bearing and the main bearing shells from the cylinder block and mark them accordingly.