If it is not possible to use the stand, disassembly should be done by placing the engine on a solid workbench, or by placing it securely on a hard 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 to be changed include:
- Alternator with support bracket (see chapter Engine Electrical Systems);
- Arms of fastening of the steering pump, air conditioner compressor (depending on configuration);
- High voltage wires and spark plugs - petrol models (see chapters Vehicle settings and routine maintenance and Engine Electrical Systems);
- Components of power supply systems and reducing the toxicity of exhaust gases (see chapter Power supply systems, release and reduction of toxicity of exhaust gases);
- Vacuum Pump - Diesel Models (see chapter Brake system);
- Thermostat with its own cover (see chapter Engine cooling, interior heating and air conditioning systems);
- Guide tube for the dipstick for measuring the level of impellent oil;
- All sensors and switches;
- Inlet pipeline and exhaust manifold (see chapter Power supply systems, release and reduction of toxicity of exhaust gases);
- Oil filter (see chapter Vehicle settings and routine maintenance);
- Suspension support of the power unit;
- Clutch assembly - models with manual transmission (see chapter Clutch and drive shafts);
- Flywheel/Drive Disc (see Section Removal, condition check and installation of a flywheel/drive disk).
When removing external components from an old engine, try to remember the characteristic features of their installation. Record the seating positions of gaskets, seals, distance rings and bushings, pins, brackets, washers, bolts and other small parts in a notebook.
When choosing a scheme using an abbreviated block set 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 (for possible alternatives to overhaul schemes see Section Alternative options for engine reconditioning schemes).
When carrying out a complete overhaul of an old unit, disassemble it and remove all internal components. The following is the best order for removing assemblies and parts:
- Inlet pipeline and exhaust manifold;
- Timing cover;
- Timing drive covers with bolts;
- Timing drive (timing belt / chain with gears / sprockets, intermediate rollers and tensioners);
- Camshafts with valve drive components;
- cylinder head;
- Water pump;
- Oil pan;
- Oil intake with strainer;
- Front cover/oil pump;
- Connecting rod and piston assemblies;
- crankshaft and main bearings;
Before disassembling the engine, prepare the following materials, tools and parts:
- Standard set of locksmith tools;
- A set of cardboard or plastic containers/plastic bags for organized storage of small components;
- Scraper for cleaning mating surfaces;
- Countersink for removing stepped wear in the upper part of the cylinders;
- Puller for dismantling the vibration damper;
- Micrometer set;
- Telescopic caliper;
- Plunger Type Dial Meter (DTI);
- Valve spring compression tool;
- Hone for processing cylinder mirrors;
- Tool for cleaning grooves for installing piston rings;
- Electric drill;
- A set of taps and lerok;
- Wire brushes;
- Cylindrical brushes for cleaning oil galleries;
- Solvent.
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