Engine Disassembly Procedure

Crankshaft and Piston Components 1. Flywheel
2. Rear Mounting Flange
3. Rear Crankshaft Seal Retainer
4. Oil Filter
5. Oil Pressure Warning Switch
6. Alternator Bracket
7. Main Bearing Cap
8. Thrust Washer
9. Main Bearing Insert
10. Crankshaft
11. Front Crankshaft Seal
12. Oil Pump
13. Gasket
14. Right Engine Mount Bracket
15. Water Pump
16. O-ring
17. Knock Sensor
18. Gasket
19. Rear Crankshaft Seal
20. Compression Piston Ring, Top
21. Oil Control Ring Rails
22. Compression Piston Ring, Bottom
23. Oil Control Ring Expander
24. Piston Pin
25. Connecting Rod
26. Connecting Rod Bearing Inserts
27. Connecting Rod Bearing Cap
28. Compression Piston Ring, Top
29. Oil Control Ring Rails
30. Piston Pin
31. Front Drive Plate Spacer
32. Rear Drive Plate Spacer
33. Drive Plate
34. Rear Mounting Flange

The engine is easiest to disassemble and service on a portable engine stand designed for engine repair. Such stands are often available for rental. Before mounting the engine on the stand, remove the flywheel with clutch assembly (or the torque converter drive plate) and the rear crankshaft seal retainer.
If no stand is available, the engine can be disassembled while secured to a sturdy workbench or the floor. When disassembling without a stand, handle the engine with great care.
If you are purchasing a remanufactured engine, first remove all ancillary components so they can be reinstalled in exactly the same way as during an independent overhaul. These components include:
– alternator and brackets;
– exhaust emission control components;
– ignition distributor, spark plugs and high-tension leads;
– thermostat and thermostat housing cover;
– water pump and other cooling system components;
– electronic fuel injection components;
– intake and exhaust manifolds;
– oil filter;
– engine mount components;
– flywheel (or torque converter drive plate);
– rear mounting flange.

* When removing ancillary components from the engine, pay special attention to parts that may be needed during engine assembly. Mark gaskets, seals, spacer sleeves, dowels, bolts, washers, nuts, etc., so they can be returned to their original positions.

If a short block assembly (i.e., cylinder block with crankshaft and piston assemblies installed) is to be installed, also remove the cylinder head, oil pan and oil pump. The remaining short block with crankshaft and piston assemblies can then be sent for repair.
If a complete overhaul with full disassembly is planned, the engine must be fully disassembled and the components removed in the following order:

– intake and exhaust manifolds;
– cylinder head cover;
– timing belt covers;
– cylinder head;
– oil pan;
– oil pump;
– piston and connecting rod assemblies;
– rear crankshaft seal retainer;
– crankshaft with main bearings.
Before disassembly and overhaul procedures, make sure you have all the required equipment and tools, listed below. (Subsection 3.1.2.15 lists the tools needed for assembly.)
– standard tool set;
– small trays or plastic bags for storing removed parts;
– scraper for removing old gasket material;
– ridge reamer for removing cylinder ridges;
– micrometers;
– set of telescoping gauges;
– set of dial bore gauges;
– valve spring compressor;
– cylinder hone;
– ring groove cleaning tool;
– electric drill;
– tap and die set;
– wire brushes;
– pipe cleaners for cleaning oil passages;
– solvent.