Engine disassembly

Cylinder head removal• Loosening sequence

• Inspect combustion chambers and ports

• Keep parts in order until inspected

Copyright 2003 Gary Lewis - Dave Capitolo

• Note location of different length bolts

• Inspect gasket seal

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

• Note direction of oil holes in rocker shafts• Burned surfaces caused by gasket failure• Carbon deposits caused by oil

• Note direction of offset rocker arms

Engine disassembly

For OHC cylinder heads . . .• Keep rockers/cam followers in order

For OHV cylinder heads . . .• Keep rockers/cam followers in order long enough for inspection or if reused

• Measure head thickness at teardown

• Keep valves in order long enough to check installed height

Engine disassembly

Lifters• Safer to remove from the bottom

• Check for lack of rotation

• Check for dished or pitted bases

• Remove cam with engine standing on back

Engine disassembly

Connecting rods• Check for correct rod numbering

Importance• Caps back on the same connecting rod

• If rods were already marked, verify position• Engrave cap and rod on the same side

• Housing bores do not get distorted

• Rods back in the samecylinder, facing the correct way

Engine disassembly

Connecting rods• Bearing tangs on same side

For disassembly . . .• Use rubber tubing to protect crank pin

• Valve reliefs• Pin offset major thrust side• Chamfer facing crankshaft radius

• Remove pistons one-at-a-time

• Use hammer handle to push piston assembly out

Engine disassembly

Mains• Check for correct main cap numbering

• Inspect thrust surface

• If mains were already marked, verify position

• Stamp cap and block for position & direction (torqued)

Engine disassembly

Ridge reaming• To remove ridge at top of cylinder

• Do not cut into ring travel

• To protect ring lands from damage

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