Note location of different length bolts Engine disassembly Cylinder head removal Loosening sequence Note location of different length bolts Inspect combustion chambers and ports Inspect gasket seal Keep parts in order until inspected Copyright 2003 Gary Lewis - Dave Capitolo

Engine disassembly Cylinder head disassembly Shock spring retainers with piston pin or socket Use spring compressor for removal

Engine disassembly Cylinder heads Deburr valve stem tip with file or grinder to protect guide

Engine disassembly Cylinder heads Check installed valve stem height while valves are still in order

Engine disassembly Other tips during disassembly Clean combustion chambers caused by water Carbon deposits caused by oil Burned surfaces caused by gasket failure Note direction of oil holes in rocker shafts Note direction of offset rocker arms

Engine disassembly For OHC cylinder heads . . . Keep rockers/cam followers in order Measure head thickness at teardown For OHV cylinder heads . . . Keep rockers/cam followers in order long enough for inspection or if reused Keep valves in order long enough to check installed height

Engine disassembly Lifters Safer to remove from the bottom Check for dished or pitted bases Check for lack of rotation Remove cam with engine standing on back

Engine disassembly Connecting rods Check for correct rod numbering Engrave cap and rod on the same side If rods were already marked, verify position Importance Caps back on the same connecting rod Rods back in the same cylinder, facing the correct way Housing bores do not get distorted

Engine disassembly Connecting rods Bearing tangs on same side Chamfer facing crankshaft radius Pin offset major thrust side Valve reliefs For disassembly . . . Use rubber tubing to protect crank pin Use hammer handle to push piston assembly out Remove pistons one-at-a-time

Engine disassembly Mains Check for correct main cap numbering Stamp cap and block for position & direction (torqued) If mains were already marked, verify position Inspect thrust surface

Engine disassembly Ridge reaming To remove ridge at top of cylinder To protect ring lands from damage Do not cut into ring travel

Engine disassembly Timing chain/gear removal ½” slack serviceable on timing chain engines Replace timing components as a set .006” wear limit for timing gear backlash Chain tensioners on OHC

Engine disassembly Removing cam bearings Expandable or exact size drivers Correct fit is important, so bore does not get scored

Engine disassembly Removing galley plugs Heat plug red hot Apply paraffin Remove plug

Engine disassembly Removing core plugs (cup style) Turn plug in bore with a blunt punch Remove with rolling head pinch bar . . . or pliers

Engine disassembly Removing core plugs (dish style) Use blunt punch to dent center of plug Remove plug May have to drill & use slide hammer