Removal of belts and ancillaries

After removing the engine, we begin to carefully dismantle it. We start by unfastening all belts and accessories.

Throughout the process we take care to ensure accurate reassembly by marking each part and bolt as it is removed.

We then remove all coils and wires, the water and oil pumps, alternator, power steering pump and crankshaft pulley. Any other ancillaries or pulleys present are also taken off, organised and labelled.

Removal of the bare components of the engine.

Next, we remove the bare engine components – including the sump cover, timing cover, intake manifold, clutch and flywheel, valve covers and rear engine cover.

We then organise these components on a board beside their matching bolts.

Removal of the rocker arms and pushrods.

We continue by unscrewing the now visible pushrods and rocker arms. This is the first step to dismantling the cylinder heads’ valvetrain.

We then inspect the rocker arms and pushrods – specifically at the contact points – ensuring they are not damaged or worn.

After this, the valve train’s lifter retainers and lifters are removed, too.

Every component is closely inspected for damage and replaced with new ones if necessary. The decision to replace damaged parts is double-checked.

Removal of the cylinder head.

Our next step is to proceed with removing the cylinder head bolts. This is done safely by alternating from outside to inside before removing the cylinder heads from the block. This prevents the head from warping when we release the torque.

Timing chain and the camshaft removal.

The sprockets connecting the crankshaft to the camshaft are removed along with the timing chain. We then carefully lift the camshaft from the engine, preventing any scraping or damage.

Piston rod caps removal

One by one, our technicians begin to remove the piston rod caps, keeping all of them together as a set.

When this is done, protectors are placed on each rod stud to avoid any damage to the cylinder walls as they are removed.

Cleaning of cylinder tops.

We then remove all carbon build-up from the cylinder tops, using a cylinder ridge reamer. Once cleaned, we pull each piston out carefully and individually.

Our mechanics diligently ensure that no damage or defacement of the cylinder walls results during this process.

Inspection of the crankshaft.

Having disassembled most of the engine, we move on to deconstruct the crankshaft.
This process is done by rotating the engine 180 degrees before removing bearing caps from the crankshaft. We then unfasten the main bearings themselves, along with the crankshaft.

We examine all bearing surfaces on the crankshaft for any scratches, indentations or warping that may have developed through general wear, over heating or oil starvation.

If any damage is visible, it is sent on to our machine technicians for a second inspection to determine whether it should be repaired or replaced.

Preparation of the engine and components for reassembly

Cleaning all detached components.

Now that the engine is completely disassembled, all components that are going to be reused are organised on a table. We then thoroughly clean all parts individually.

We use warm water and detergent to wash the parts, removing any old gasket material that may remain. We then blow-dry the parts with compressed air, ensuring complete removal of moisture.

Clean the engine block.

Before we reassemble the engine, it is essential to thoroughly clean the engine block. We do this in the same way as with the parts, by removing all old gasket material, and cleaning thoroughly with warm water and detergent.

During this process we take the opportunity to re-check the block and heads for any damage. Some previously indiscernible scratches/indentations may become visible after cleaning. After verifying their condition, we blow them dry with compressed air.

Inspection of the cylinder walls.

Once the block is clean and dry, we once again inspect the cylinder walls for any scratching or scoring.

If we find any serious signs of damage, we send it to be double-checked – and if necessary, machined.

If the walls are in acceptable condition, we lightly hone them with a cylinder honing tool, smoothing out the surfaces.

Once the walls are honed, we spray them with water resistant lubricant. This process makes it easier to seat the piston rings and also prevents the walls from rusting.

Glow plugs Removal.

We then remove and replace (when requested) the engine’s glow plugs with a brass punch and hammer, we tap the glow plugs inward and pull them out at the opposite end with pliers.

The new glow plugs are installed with a gentle tap into place. We inspect each one to ensure it is flush and even. Once we have completed this, the engine block is ready for reassembly.

Installation of new piston rings.

Before reassembling the engine block, we prepare the pistons by installing new piston rings.

To avoid future issues with the engine, we carefully install these. By doing this in a very specific order, we take into account that each manufacturer tends to provide closely detained specifications that can vary the function of piston rings.

Installation of new camshaft bearings.

We then install new camshaft bearings, applying a thick layer or assembly lube to them once finished.

Reassembly of the engine

Re-installation of the crankshaft, main bearings, and caps.

We once again flip the engine upside-down, to easily install the main bearings, crankshaft and caps.

Each bearing and contact surface is completely lubricated with assembly grease before we install each main bearing cap tightly, by hand.

If necessary, we also install a seal on to the rear bearing cap.

Once all caps are fitted, we torque town each cap according to specifications. We take particular care to do this in correct sequence. This prevents any possibility of warping the crankshaft.

Once the crankshaft is installed, we check that it runs smoothly by rotating it.

Installation of pistons.

We then move on to fitting the pistons. We install new bearings onto each rod before installing them into the machine.

The piston rings are compressed with a tool before we lower them down into the cylinder and onto the crankshaft journal.

Once we have lowered the piston into the cylinder, we rotate the engine once more to install its connecting rod end cap. This process is repeated for each piston.

Installation of camshaft.

Applying assembly lube first, we then install each of the camshaft journals and cam lobes onto the engine block. As per the rest of the installation procedure, we take extra precautions to prevent scratching or scoring to any of the bearings.

Installation of timing components.

We’re now ready to install all timing parts, i.e. the timing chain and cam and crank sprockets.

We install the new sprockets and clock them by turning the cam and crankshaft until the correct cylinders are at TDC. We line up the marks on the sprockets in a specific order.

Testing the crankshaft.

Now that the rotating assembly is fully assembled, we rotate the crankshaft by hand again, ensuring all sprockets are installed correctly. After this, we fit the timing chain cover and also cover the rear engine.

Any gaskets or seals pressed into the engine covers are replaced with new ones.

Installation of the oil sump.

We move on to install the oil pan using a gasket.

We lay a thin but thorough bead of silicone gasket maker along all contact points between the pan and gaskets.

Installation of head gaskets and head.

At this stage, we move on to assembling the engine’s top half.

We install new head gaskets, securing them by hand before torqueing the head bolts.

We follow torque specifications and sequence to ensure correct installation according to your specific engine.

Reinstallation of the valve train.

We now fit the rest of the valve train. First, we reassemble all lifters, guide retainer, pushrods and rocker arms.

All components are generously layered with assembly lube during installation. By doing this, we prevent them from wearing when the engine is started for the first time.

Install covers and intake manifold.

Install the valve covers, rear engine cover, and then intake manifold.

Use the new gaskets that should be provided with your rebuild kit, remembering to lay a bead of silicone around any corners or edges where mating surfaces meet, and around the water jackets.

Install the water pump, exhaust manifolds, and flywheel.

At this point the engine should almost be fully reassembled, with only the water pump, exhaust manifolds, flexplate or flywheel, and accessories left to install.

Install the water pump and manifolds using the new gaskets provided in your rebuild kit, and then proceed to install the rest of the accessories in the reverse of the order in which you removed them.