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
