Table of contents: 1.4L engines 🠇 1.6L engines 🠇
1. Remove the crankshaft timing pulley and oil pump as described in chapter 2A.
2. Remove the pistons and connecting rods as described in paragraph 9. Unless any work is to be done on the pistons and connecting rods, there is no need to remove the cylinder head or remove the pistons from the cylinders. You just need to move the pistons up far enough to clear the connecting rods from the crankshaft journals.
3. Check the crankshaft end clearance as described in paragraph 13, and then proceed as described below.
1.4L engines
4. Working from the outside of the cylinder block, remove all small (M6) bolts securing the main bearing housing to the base of the cylinder block. Note the installation depth of the left and right crankshaft oil seals in the cylinder block/main bearing housing.
5. Working in a crisscross pattern, evenly and gradually loosen the 10 large (M11) main bearing housing bolts, one turn at a time. Once all the bolts are loosened, completely unscrew them from the housing.
6. After unscrewing all the bolts, carefully remove the main bearing housing, carefully moving it away from the base of the cylinder block. Remove the lower main bearing shells and use adhesive tape to secure them in the appropriate places on the housing. If the two mounting pins are not secure, remove them and store them in a safe place along with the housing.
7. Remove the crankshaft and discard both seals. Remove the oil pump drive chain from the end of the crankshaft. If necessary, remove the drive sprocket and woodruff key.
8. Remove the upper main bearing shells and store them together with the corresponding lower bearing shells. Also remove the two thrust washers (installed on both sides of main bearing No. 2) from the cylinder block.
1.6L engines
9. Remove the bolts and the left and right crankshaft oil seal housings from each end of the cylinder block, noting the position of the dowel pins. If the dowel pins are not secured, remove them and store them in a safe place along with the housings.
10. Remove the oil pump drive chain and remove the drive sprocket from the end of the crankshaft. Remove the woodruff key and store it in a safe place along with the sprocket.
11. The main bearing caps must be numbered 1 through 5, starting from the end of the engine where the gearbox is attached. If there are no markings, mark the caps accordingly using a center punch or paint.
12. Unscrew the main bearing cap mounting bolts and remove the caps. Remove the lower main bearing shells and tape them to their respective caps and store them in a safe place.
13. Carefully remove the crankshaft, being careful not to displace the upper main bearing shells.
14. Remove the upper bearing shells from the cylinder block and use adhesive tape to attach them to the corresponding covers and put them in a safe place. Remove the thrust washers from main bearing No. 2 and store them in a safe place along with the corresponding bearing cap.