Engine - dismantling
1 The need for dismantling will have been dictated by wear or noise in most cases. Although there is no reason why only partial dismantling cannot be carried out to renew such items as the timing chain or crankshaft rear oil seal, when the main bearings or bigend bearings have been knocking, and especially if the vehicle has covered a high mileage, then it is recommended that a complete strip down is carried out and every engine component examined.
2 Position the engine so that it is upright on a bench or other convenient working surface. If the exterior is very dirty it should be cleaned before dismantling using paraffin and a stiff brush or a water-soluble solvent.
3 Remove the coolant pipe from the side of the engine by disconnecting the hose clips and the securing bolt.
Engine lateral coolant pipe connections (arrowed)
4 If not already done, drain the engine oil.
5 Remove the dipstick and unscrew and discard the oil filter.
6 Disconnect the HT leads from the spark plugs, release the distributor cap and lift it away complete with leads.
7 Unscrew and remove the spark plugs.
8 Disconnect the breather hose from the inlet manifold and remove it complete with the oil filler cap.
9 Disconnect the fuel and vacuum pipes from the carburettor and unbolt and remove the carburettor.
10 Unbolt the thermostat housing cover and remove it, together with the thermostat.
11 Remove the rocker cover.
12 Remove the rocker shaft assembly (four bolts).
13 Withdraw the pushrods, keeping them in their originally fitted order.
14 Remove the cylinder head, complete with manifolds.
15 Remove the bolt that holds the distributor clamp plate to the cylinder block and withdraw the distributor.
16 Unbolt and remove the fuel pump.
Unbolt and remove the fuel pump
17 Remove the oil pump.
18 Pinch the two runs of the coolant pump drivebelt together at the pump pulley to prevent the pulley rotating and release the pulley bolts.
19 Release the alternator mounting and adjuster link bolts, push the alternator in towards the engine and remove the drivebelt.
Alternator retaining and drivebelt adjustment bolts
20 Unbolt the alternator bracket and remove the alternator.
Alternator mounting bracket
21 Unbolt and remove the coolant pump.
Unbolt and remove the coolant pump
22 Unscrew the crankshaft pulley bolt. To do this, the flywheel starter ring gear will have to be jammed to prevent the crankshaft from turning.
Unscrew the crankshaft pulley retaining bolt
23 Remove the crankshaft pulley. If this does not pull off by hand, carefully use two levers behind it placed at opposite points.
24 Place the engine on its side and remove the sump. Do not invert the engine at this stage, or sludge and swarf may enter the oilways.
25 Unbolt and remove the timing chain cover.
Remove the timing chain cover
26 Take off the oil slinger from the front face of the crankshaft sprocket.
Removing the crankshaft oil slinger
27 Slide the chain tensioner arm from its pivot pin on the front main bearing cap.
Sliding off the chain tensioner arm
28 Unbolt and remove the chain tensioner.
29 Bend back the lockplate tabs from the camshaft sprocket bolts and unscrew and remove the bolts.
Bending back the camshaft sprocket bolt locktabs
30 Withdraw the sprocket complete with timing chain.
31 Unbolt and remove the camshaft thrust plate.
Unbolting the camshaft thrust plate
32 Rotate the camshaft until each cam follower (tappet) has been pushed fully into its hole by its cam lobe.
33 Withdraw the camshaft, taking care not to damage the camshaft bearings.
Withdrawing the camshaft
34 Withdraw each of the cam followers, keeping them in their originally fitted sequence by marking them with a piece of numbered tape or using a box with divisions.
Lift out the cam followers (tappets), using a valve grinding tool
35 From the front end of the crankshaft, draw off the sprocket using a two-legged extractor.
36 Check that the main bearing caps are marked F (Front), C (Centre) and R (Rear). The caps are also marked with an arrow which indicates the timing cover end of the engine, a point to remember when refitting the caps.
37 Check that the big-end caps and connecting rods have adjacent matching numbers facing towards the camshaft side of the engine. Number 1 assembly is nearest the timing chain end of the engine. If any markings are missing or indistinct, make some of your own with quick-drying paint.
Connecting rod and big-end cap markings (arrowed)
38 Unbolt and remove the big-end bearing caps. If the bearing shell is to be used again, tape the shell to the cap.
39 Now check the top of the cylinder bore for a wear ridge. If one can be felt, it should be removed with a scraper before the piston/rod is pushed out of the cylinder.
40 Remove the piston/rod by pushing it out of the top of the block. Tape the bearing shell to the connecting rod.
41 Remove the remaining three piston/rod assemblies in a similar way.
42 Unbolt the clutch pressure plate cover from the flywheel. Unscrew the bolts evenly and progressively until spring pressure is relieved, before removing the bolts. Be prepared to catch the clutch driven plate as the cover is withdrawn.
43 Unbolt and remove the flywheel. It is heavy, do not drop it. If necessary, the starter ring gear can be jammed to prevent the flywheel rotating. There is no need to mark the fitted position of the flywheel to its mounting flange as it can only be fitted one way. Take off the adapter plate (engine backplate).
44 Unbolt and remove the crankshaft rear oil seal retainer.
Crankshaft rear oil seal retainer
45 Unbolt the main bearing caps. Remove the caps, tapping them off if necessary with a plastic-faced hammer. Retain the bearing shells with their respective caps if the shells are to be used again, although unless the engine is of low mileage this is not recommended.
46 Lift the crankshaft from the crankcase and lift out the upper bearing shells, noting the thrustwashers either side of the centre bearing. Keep these shells with their respective caps, identifying them for refitting to the crankcase if they are to be used again.
47 With the engine now completely dismantled, each component should be examined, as described in the following Section before reassembling.