If the stand is not available, then the engine can be disassembled by placing it on the floor on wooden blocks. Be especially careful not to tilt or drop it when working without a stand.
If you are going to purchase a remanufactured engine, then all of the following components must be removed first in order to install them on the new engine, if required. This also applies to the case of self-repair of the engine.
When removing attachments from the engine, pay special attention to parts that may be useful or important during reassembly. Note the positions of gaskets, seals, spacers, pins, brackets, washers, bolts, and other small items.
Left engine mounting bracket M40.
- Generator and brackets
- Components of toxicity control systems
- Ignition distributor, high voltage wires and spark plugs
- Thermostat and housing cover
- Water pump
- Fuel System Components and Fuel Injection System/ Carburetor
- Inlet pipeline and exhaust manifold
- Oil filter and oil pressure sensor
- Engine mounting brackets
- Clutch and flywheel/drive plate
- Rear engine cover (if applied)
If a small set with a cylinder block is purchased, it consists of an assembled block, crankshaft, pistons and connecting rods, then the cylinder head, sump and oil pump should also be rearranged. For more information about the different options available, 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
- Inlet pipeline and exhaust manifold
- Timing belt or timing chain covers
- Timing chain/belt
- Water pump
- cylinder head
- Pallet
- Oil pump
- Pistons / brass assy
- Crankshaft and main bearings
- Camshaft
- Rocker shafts and rocker arms (engines M10, M20 and M30)
- Pushers and hydraulic lifters (M40 engine)
- Valve spring holders and springs
- valves
Before starting disassembly and overhaul operations, make sure that the following tools and accessories are available. Also refer to Section Engine assembly sequence during overhaul 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 storage compartments for hydraulic lifters (M40 engine)
- Gasket scraper
- Countersink for chamfering cylinders
- Vibration damper puller
- Micrometers
- Telescopic meters
- Dial indicator
- Valve spring compressor
- Hone for cylinder surfaces
- Piston ring groove cleaning tool
- Electric drill
- Set of lerok and taps
- Wire brushes
- Oil line brushes
- Cleaning solvent