The objective of this procedure is to show you how to assemble the accessories to the engine. Install accessories, flexplate, flywheel and clutch assembly and tighten centerbolt.
Part 1. Preparation and safety
- Assemble the accessories to the engine.
Whenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include:
- Work clothing - such as coveralls and steel-capped footwear
- Eye protection - such as safety glasses and face masks
- Ear protection - such as earmuffs and earplugs
- Hand protection - such as rubber gloves and barrier cream
- Respiratory equipment - such as face masks and valved respirators
If you are not certain what is appropriate or required, ask your supervisor.
- Take care and use the correct lifting technique when lifting heavy loads.
- Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.
Points to note
- Check all notes made during disassembly to ensure all parts are correctly fitted.
Part 2: Step-by-step instruction
- Install miscellaneous accessories
Check your notes from the disassembly again. The engine has to be brought back to the same state it was in when it came out of the chassis. Replace any sensors, plugs, or brackets. You might even go as far as reinstalling your fuel injection system or your carburetor.
- Install flexplate
All engines will need the flexplate or flywheel torqued in place. The same screwdriver technique will keep the crank from moving while you tighten the bolts. Automatic transmission engines will only need the flexplate for now.
- Install flywheel and clutch assembly
For engines with a flywheel and clutch assembly, the clutch pressure plate and disc should be installed.
When the flywheel is torqued in place, set the friction disc into a centered position. A plastic alignment tool will center this disc where it needs to be while you fit the pressure plate on and tighten its screws. When the pressure plate is torqued onto the flywheel, the disc will be pinched into it's proper position and won't move. Now pull out the alignment tool.
- Tighten centerbolt
For most engines, the torque rating for the centerbolt is usually the highest in the whole motor so make sure that you have the crank held still while you tighten this bolt
Decide now how much else you need to bolt on to the engine. Keep in mind that you might still need to roll the engine through a doorway or past some other obstacle to get it to the hoisting location, but the aim is to be close to a completed assembly, ready for installation back in the vehicle.