If a stand is not available, the engine can be disassembled by placing it on the floor on wooden blocks. Be especially careful not to tilt it or drop it when working without a stand.
If you are going to buy a rebuilt engine, all the components listed below must be removed first in order to install them on a new engine, if required. This also applies if you are doing a major engine overhaul yourself.
When removing engine attachments, pay special attention to parts that may be useful or important for subsequent assembly. Note the location of gaskets, seals, spacers, pins, brackets, washers, bolts, and other small parts.
Left engine mounting bracket M40.
- Generator and brackets
- Components of toxicity reduction systems
- Ignition distributor, high-voltage wires and spark plugs
- Thermostat and housing cover
- Water pump
- Fuel system components and fuel injection system/carburetor
- Intake manifold and exhaust manifold
- Oil filter and oil pressure sensor
- Engine Mounting Brackets
- Clutch and flywheel/drive disc
- Rear engine cover (if applied)
If you purchase a small kit with a cylinder block, consisting of an assembled block, crankshaft, pistons and connecting rods, then you should also reinstall the cylinder head, oil pan and oil pump. For more information on the various possible options, see Section Engine Overhaul Options.
If a complete overhaul is planned, the engine must be disassembled and the internal components removed in the following general sequence:
- Cylinder head cover
- Intake manifold and exhaust manifold
- Timing Belt or Chain Covers
- Timing chain/belt
- Water pump
- Cylinder head
- Pallet
- Oil pump
- Pistons/rods assemblies
- Crankshaft and main bearings
- Camshaft
- Rocker shafts and rocker arms (engines M10, M20 and M30)
- Pushers and hydraulic lifters (m40 engine)
- Valve spring retainers and springs
- Valves
Before beginning disassembly and major repair operations, ensure that the following tools and accessories are available. Also refer to Section Sequence of engine assembly during major repairs for a list of tools and materials needed to assemble the engine.
- General purpose hand tools
- Small cardboard boxes or plastic bags for storing parts
- Metal box with compartments for storing hydraulic lifts (engine M40)
- Gasket scraper
- Chamfer countersink for cylinders
- Vibration Damper Puller
- Micrometers
- Telescopic meters
- Dial indicator
- Valve spring compressor
- Cylinder Surface Honing
- Piston Ring Groove Cleaning Tool
- Electric drill
- Set of dies and taps
- Wire brushes
- Brushes for oil lines
- Cleaning solvent