General description
1. Ideally, the engine should be mounted on a special stand, but if one is not available, place the engine on a heavy workbench at a comfortable working height. Otherwise, lower the engine to the floor.
2. It is very important to keep it clean. If the engine is dirty, it should be cleaned with kerosene.
3. If the engine oil appears heavily contaminated, do not turn the engine over until the oil pan has been removed.
4. When removing parts, wash them in a bath of kerosene. Do not immerse parts with internal oil grooves in kerosene. Clean the oil grooves with plastic sticks for cleaning boring holes.
5. It is recommended to prepare more containers for storing small parts to prevent loss and confusion during installation.
6. Always purchase complete gasket sets when disassembling an engine. Keep the old gaskets as they can be used as a reference when looking for new gaskets
7. Where possible, after removing the relevant components, screw the nuts, bolts and washers back into place; this will firstly protect the threads and secondly will be useful during assembly.
8. Secure the defective components to compare them with the new ones.
9. Many engine components are secured with socket head bolts and special tools are required to remove and install these bolts.
10. Before starting work, carefully read each relevant Chapter of this Section to prepare special tools in advance. Many components (gaskets, seals, some bolts) must be replaced during assembly; if necessary, purchase any new components required before starting work.
11. Before beginning complete engine disassembly, the following ancillary components may be removed once the engine has been removed from the vehicle:
- a) Intake and exhaust manifolds (if necessary)
- b) Starter
- c) Rear cooling channel and hoses
- d) Oil pressure sensor
- e) Oil temperature sensor (depending on the model)
- f) Oil level sensor (depending on the model)
- g) Knock sensor (depending on the model)
- h) TDC sensor (depending on the model)
- i) Distributor components
- j) Fuel pump (depending on the model)
- k) Thermostat/casing (models N16NZ2, 1.8 and 2.0 liters)
- l) Power steering pump and mounting bracket (depending on the model)
- m) Generator mounting bracket
- n) Engine lifting eyes
- o) Crankcase breather/dipstick tubes
- p) Intake manifold mounting bracket (depending on the model)
12. To ensure maximum mileage and limit the possibility of trouble, the engine must not only be properly assembled, but it must also be spotlessly clean. All oil grooves and coolant passages must be free of debris, and all washers must be installed in their original positions. Lubricate all bearings and other moving surfaces with oil.
13. Before starting assembly, replace any mounting bolts or struts with damaged threads.
14. Purchase a torque wrench, angular torque template, sockets, oil can, thick (lint free) rags, and a set of gaskets and seals along with a new engine oil filter
15. You will also need new bolts for fastening the cylinder head, flywheel, connecting rod and main bearing caps.
16. Finally, install the removed add-on components listed in step 12.
17. Next, proceed to Chapter 37.
Visitor comments