General description
1. Ideally, the engine should be mounted on a suitable stand, but if this is not available, place the engine on a heavy duty workbench at a comfortable working height. Otherwise, lower the engine to the floor.
2. It is very important to keep clean. If the engine is dirty, it must be cleaned with kerosene.
3. If the engine oil seems heavily contaminated, do not turn the engine over until the sump is removed.
4. When removing parts, wash them in a kerosene bath. Do not immerse parts with internal oil grooves in kerosene. Clean the oil grooves with plastic bore cleaning sticks.
5. It is recommended to prepare more containers for storing small parts in order to prevent loss and confusion during installation.
6. Always purchase complete gasket sets when disassembling an engine. Keep old gaskets, as they can be used as a reference when looking for new gaskets
7. Where possible, after removing the relevant components, screw nuts, bolts and washers into place, this will firstly protect the threads, and secondly will be useful during assembly.
8. Fix unusable components to compare them with new ones.
9. Many engine components are attached with socket head bolts and require special tools to remove and install these bolts.
10. Before starting work, carefully read each relevant Chapter of this Section in order to prepare special tools in advance. Many components (gaskets, seals, some bolts) must be replaced during assembly; if necessary, purchase the required new components before starting work.
11. Before starting a complete engine disassembly, the following accessory components can 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/shroud (models N16NZ2, 1.8 and 2.0 liters)
- l) Power steering pump and mounting bracket (depending on the model)
- m) Alternator Mounting Bracket
- n) Engine lifting eyes
- o) Dipstick/crankcase breather tubes
- p) Intake manifold mounting bracket (depending on the model)
12. To ensure maximum mileage, limit the possibility of trouble, the engine must not only be properly assembled, but it must also be spotlessly clean. All oil and coolant grooves must be free of obstruction and all washers must be installed in their original positions. Lubricate all bearings and other moving surfaces with oil.
13. Before assembly, replace any mounting bolts or stands with damaged threads.
14. Purchase a torque wrench, an angular torque template, sockets, an oil canister tight (lint-free) rags, and a set of gaskets and seals along with a new oil filter for the engine
15. You will also need new bolts for fastening the cylinder head, flywheel caps, connecting rod and main bearings.
16. At the end of the assembly, install the removed attachments listed in point 12.
17. Next, go to Chapter 37.
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