Engine Disassembly

PRELIMINARY COMPONENTS

1. Remove distributor.
2. Remove alternator.
3. Remove air pump.
4. Remove oil filter.
5. Remove fan and pulley.
6. Remove water pump.
7. Remove thermostat.

MANIFOLD & CARBURETOR ASSEMBLY

1. Disconnect the vacuum sensing tube (distributor-carburetor) from carburetor.
2. Disconnect the ventilation hose from the ventilation valve at intake manifold.
3. Remove the bolts attaching intake manifold to the cylinder head and remove intake manifold and carburetor assembly.

Fig. 1 Cylinder head bolt tightening sequence:

REMOVING CYLINDER HEAD

1. Remove the attaching nuts and the rocker arm cover and gasket.
2. Remove two semicircular oil seals.
3. Install the flywheel brake (49 0221 030A) or other suitable tool to the flywheel.
4. Remove the locknut and washer and slide the distributor drive gear off the camshaft.
5. With the spanner (49 0164 631A) or other suitable tool, loosen the locknut holding the camshaft sprocket.
6. Remove the bolt that attaches the cylinder head to the timing chain cover.
7. Loosen the cylinder head bolts in the reverse order of tightening, Fig. 1. To avoid cylinder head distortion, loosen the bolts a few turns at a time until they are all loose.
8. Remove the rocker arm assembly.
9. Pull the camshaft rearward and separate the camshaft from the camshaft sprocket. Remove the camshaft sprocket.
10. Remove the camshaft bearing halves from the cylinder head.
11. Remove the cylinder head and gasket. When removing only the camshaft or the cylinder head, the timing chain should be lifted upward to prevent the slipper head of the chain adjuster from flying out and causing a difficulty in adjusting the timing chain.

VALVE & VALVE SPRING

1. Remove the carbon inside the combustion chamber.
2. Using suitable spring compressor, compress valve springs.
3. Remove the taper sleeves, upper spring seat, valve springs and lower spring seat.
4. Remove the valve, then place the taper sleeves, upper spring seats, valve springs, lower spring seats and valves in order for reassembling.

CRANKSHAFT PULLEY

1. Install the brake (49 0221 030A) or other suitable tool to the flywheel.
2. Remove the pulley bolt and pull the pulley off the front end of the crankshaft.

CLUTCH ASSEMBLY

1. Install the brake (49 0221 030A) or other suitable tool to the flywheel.
2. Remove the bolts holding the clutch cover to the flywheel and remove the clutch cover and pressure plate assembly and clutch disc.
3. Remove the bolts attaching the flywheel to the rear end of the crankshaft.
4. Remove the brake and flywheel.

OIL PAN

1. Invert the cylinder block.
2. Remove the nuts and bolts that attach the oil pan to the cylinder block.
3. Remove the oil pan and gasket.

CHAIN COVER

1. Remove the bolts and nuts that attach the timing chain cover to the cylinder block.
2. Remove the chain cover and gaskets.
3. Remove the oil thrower from the crankshaft.

CHAIN ADJUSTER, CHAIN GUIDE STRIP & VIBRATION DAMPER

Remove the screws and bolts, and then remove the chain adjuster, chain guide strip and vibration damper.

TIMING CHAINS & SPROCKETS

1. Remove locknut and lock washer attaching oil pump sprocket.
2. Remove the crankshaft sprocket, oil pump drive chain and oil pump sprocket.
3. Remove the timing chain and crankshaft sprocket.
4. Remove the key from the crankshaft.

OIL PUMP & OIL STRAINER

1. Remove the nuts attaching the oil strainer to the oil pump and remove the oil strainer and O-ring.
2. Remove the bolts and the oil pump, O-ring and adjusting washers from the cylinder block.

PISTON & CONNECTING ROD

1. Remove the bolts from each connecting rod and remove the bearing caps.
2. Push the piston and connecting rod assembly out of the cylinder block with the handle end of a hammer until the piston rings are free from the cylinder bore. Remove the piston and connecting rod assembly from the top of the block.
3. To separate the piston and connecting rod assembly, remove the clips and the piston pin with the installer (49 0223 061). If tight, heat the piston with a piston heater.

Fig. 2 Removing rear main bearing cap:

CRANKSHAFT

1. Remove bolts that attach main bearing caps to cylinder block.
2. Remove main bearing caps and thrust washers. When removing the rear main bearing cap, use puller (49 0221 270B), Fig. 2.
3. Take out oil seal from crankshaft rear end.
4. Remove crankshaft from cylinder block.