Engine Disassembly Procedure for Overhaul Preparation

The simplest way to disassemble the engine is to mount it on a portable engine stand. Such a stand can always be borrowed relatively inexpensively from an automotive repair shop. Before mounting the engine on the stand, remove the flywheel/drive plate.

If a stand is not available, disassemble the engine by placing it on a sturdy workbench or securely on a solid garage floor. When working without a stand, make sure the engine does not accidentally tip over.

If the engine is to be replaced with a remanufactured unit, remove all attached components and external parts from the old engine and transfer them to the replacement unit. Components to be transferred include:

a) Alternator with brackets;
b) Power steering pump with brackets;
c) Emission control components;
d) Distributor, spark plug wires and spark plugs;
e) Thermostat with housing cover;
f) Water pump bypass hose/pipe;
g) Fuel injection system components;
h) Intake manifold and exhaust manifold(s);
i) Oil filter;
j) Engine mounts;
k) Clutch assembly (manual transmission);
l) Flywheel/drive plate;


When removing external components from the old engine, note their installation details. Record in a notebook the positions of gaskets, seals, spacers and bushings, dowel pins, brackets, washers, bolts and other small parts.

If the partial overhaul method is selected, using a short block consisting of the cylinder block with the crankshaft and piston/connecting rod assemblies installed, also remove the cylinder head, oil pan and oil pump from the old engine (for alternative overhaul methods, refer to the Alternative Engine Overhaul Methods section).

When performing a complete overhaul of the old engine, disassemble it and remove all internal components. The following is the recommended disassembly sequence:

a) Intake manifold and exhaust manifold(s);
b) Cylinder head cover(s);
c) Timing belt covers with bolts;
d) Timing drive (timing belt with sprockets);
e) Rocker arm assembly with camshaft(s);
f) Cylinder head(s);
g) Water pump;
h) Oil pan;
i) Oil pickup tube with screen;
j) Front cover/oil pump;
k) Piston and connecting rod assemblies;
l) Crankshaft and main bearings;

Before starting engine disassembly, prepare the following materials, tools and parts (see also the Engine Assembly Procedure section):

a) Standard set of mechanic's hand tools;
b) Set of cardboard or plastic containers/plastic bags for organized storage of small components;
c) Gasket scraper for cleaning mating surfaces;
d) Ridge reamer for removing the ridge at the top of the cylinders;
e) Puller for removing the crankshaft vibration damper;
f) Set of micrometers;
g) Telescoping gauge;
h) Dial indicator (DTI), plunger type;
i) Valve spring compressor;
j) Cylinder bore hone;
k) Piston ring groove cleaning tool;
l) Electric drill;
m) Set of taps and thread gauges;
n) Wire brushes;
o) Round brushes for cleaning oil galleries;
p) Solvent.