If a stand is not available, disassembly should be performed with the engine placed on a sturdy workbench or securely placed on a solid garage floor. When working without a stand, make sure that the engine does not accidentally tip over.
If you plan to replace the engine with a remanufactured one, remove all attachments and external components from the old one and transfer them to the replacement unit. The components that need to be re-installed include:
- Generator with support bracket (see Chapter Engine electrical equipment);
- Brackets for mounting the steering pump, air conditioning compressor (depending on the configuration);
- High-tension wires and spark plugs - gasoline models (see Chapters Routine maintenance and Engine electrical equipment);
- Components of fuel and emission control systems (see Chapter Power and exhaust systems);
- Vacuum pump - diesel models (see Chapter Brake system);
- Thermostat with its casing (see Chapter Cooling and heating systems);
- Engine oil dipstick guide tube;
- All sensors and switches;
- Intake manifold and exhaust manifold (see Chapter Power and exhaust systems);
- Oil filter (see Chapter Routine maintenance);
- Powertrain suspension mounts (see Checking the condition and replacing the powertrain suspension supports);
- Clutch assembly - models with manual transmission (see Chapter Clutch and drive shafts);
- Flywheel/drive disc (see Removal, checking condition and installing flywheel/drive disk and Removal, checking condition and installing flywheel/drive disk).
When removing external components from an old engine, try to remember the characteristic features of their installation. Record in a notebook the mounting positions of gaskets, seals, spacers and bushings, pins, brackets, washers, bolts and other small parts.
When selecting a scheme using a reduced block kit consisting of a cylinder block with a crankshaft and connecting rod and piston groups installed in it, also remove the cylinder head, oil pan and oil pump from the old unit (see possible alternative schemes for performing major repairs. Alternative options for engine repair schemes).
When performing a complete overhaul of an old unit, disassemble it and remove all internal components. The optimal order for removing units and parts is given below:
- Intake manifold and exhaust manifold;
- Timing mechanism cover;
- Timing Belt Covers with Bolts;
- Timing drive (timing belt/chain with toothed wheels/sprockets, idler rollers and tensioners);
- Camshafts with valve drive components;
- Cylinder head;
- Water pump;
- Oil pan;
- Oil intake with mesh filter;
- Front cover/oil pump;
- Connecting rod and piston assemblies;
- Crankshaft and main bearings;
Before you begin disassembling the engine, prepare the following materials, tools and parts (see also Removal and installation the timing belt cover):
- Standard set of locksmith tools;
- A set of cardboard or plastic containers/polyethylene bags for organized storage of small components;
- Scraper for cleaning mating surfaces;
- Countersink for removing stepped wear on the top of the cylinders;
- Torsional vibration damper removal tool;
- Micrometer set;
- Telescopic bore gauge;
- Dial Type Indicating Gauge (DTI);
- Valve Spring Compressor Tool;
- Hone for processing cylinder mirrors;
- Tool for cleaning piston ring grooves;
- Electric drill;
- Set of taps and dies;
- Wire brushes;
- Cylindrical brushes for cleaning oil galleries;
- Solvent.
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