1.2. Engine — Dismantling (page 2 of 3)

Detailed inforation on engine dismantling and assembly is given in the sections dealing with the servicing and overhaul (commencing at 1.3.) and these should be followed for each of the sub-assemblies or units to be dealt with.

Follow the general dismantling instructions given below. The two engine types are described under different headings.

Dismantling must be carried out in an orderly fashion to ensure that parts, such as valves, pistons, bearing caps, shells and so on, are replaced in the same positions as they occupied originally. Mark them clearly, but take care not to scratch or stamp on any rotating or bearing surfaces. A good way to keep the valves in order is by piercing them through an upside-down cardboard box and writing the number against each valve (see Fig. 1.15). Segregate together the springs and retainers with collets for each valve, if possible in small plastic bags for each individual valve.

If a proper engine dismantling stand is not available, it will be useful to make up wooden support blocks to allow access to both the top and bottom faces of the engine. The cylinder head, once removed from the block, should be supported by a metal strap, screwed to the manifold face and secured by two nuts onto the manifold studs.

The following text describes the general dismantling of the engine. Specific instructions for the removal of a certain parts can be found in the following sections.

• On one side of the engine remove the oil filter. A suitable oil filter wrench must be available. Otherwise drive the blade of a screwdriver through the side of the filter and unscrew it. The filter must be replaced in any case.
• Remove all accessible parts from the engine, including cylinder head cover, air intake and exhaust manifold (with carburettor), alternator and drive belt, ignition distributor, fuel pump, one oil pipe, cable harnesses, etc.
• Unscrew the 5 nuts securing the rocker shaft assembly. Slacken the 10 cylinder head bolts from the outside towards the inside in seve-