1. 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

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

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

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

5. 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

6. 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

7. 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

8. 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

9. 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

10. 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

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

12. 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

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

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

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

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