Engine overhaul - preliminary information

Engine removal and overhaul procedures / Engine overhaul - preliminary information

1 It is much easier to dismantle and work on the engine if it is mounted on a portable engine stand. These stands can often be hired from a tool hire shop. Before the engine is mounted on a stand, the flywheel should be removed, so that the stand bolts can be tightened into the end of the cylinder block/ crankcase.

2 If a stand is not available, it is possible to dismantle the engine with it blocked up on a sturdy workbench, or on the floor. Be very careful not to tip or drop the engine when working without a stand.

3 If you intend to obtain a reconditioned engine, all ancillaries must be removed first, to be transferred to the replacement engine (just as they will if you are doing a complete engine overhaul yourself). These components include the following:
a) Alternator (including mounting brackets) and starter motor (Chapter 5A).

b) The ignition system and HT components including all sensors, distributor, HT leads and spark plugs (Chapters 1 and 5).

c) The fuel injection system components (Chapter 4 Parts A and B) d) All electrical switches, actuators and sensors, and the engine wiring harness (Chapter 4 Parts A and B, Chapter 5B).

e) inlet and exhaust manifolds (Chapter 2A).

f) The engine oil level dipstick (Chapter 1) g) Engine mountings (Chapter 2A and B).

h) Flywheel (Chapter 28) i) Clutch components (Chapter 6) Note: When removing the external components from the engine, pay close attention to details that may be helpful or important during refitting. Note the fitted position of gaskets, seals, spacers, pins, washers, bolts, and other small components.

4 If you are obtaining a “short” engine (which consists of the engine cylinder block/ crankcase, crankshaft, pistons and connecting rods, all fully assembled), then the cylinder head, sump and baffle plate, oil pump, timing belt (together with its tensioner and covers), auxiliary belt (together with its tensioner), coolant pump, thermostat housing, coolant outlet elbows, oil filter housing and where applicable oil cooler will also have to be removed.

5 If you are planning a complete overhaul, the engine can be dismantled in the order given below:
a) Inlet and exhaust manifolds.

b) Timing be/t, sprockets and tensioner.

c) Cylinder head.

d) Flywheel driveplate.

e) Sump.

f) Oil pump.

g) Piston/connecting rod assemblies.

h) Crankshaft.

6 Before beginning the dismantling and overhaul procedures, make sure that you have all of the tools necessary. Refer to “Tools and working facilities” in the Reference Section of this manual for further information.