Engine disassembly Cylinder head removal Loosening sequence Note
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
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