Disassemble

PREPARATION

- Drain the engine oil.
- Remove transmission from engine.
- Remove the torque converter and flex plate.
- Secure the engine to an approved engine stand.

DISMANTLING
- Remove the distributor cap complete with all ignition cables and pull the vacuum pipe from the capsule.
- Remove the ignition coil bracket from the engine. Note the connection and remove the engine cable harness.
- Slacken the clips on the coolant hoses at the front of the engine.
- Remove the hoses.
- Remove the center bolt securing the fan and fan clutch unit to the water pump pulley.
- Remove the air-conditioning compressor bracket.
- Remove the alternator and bracket.
- Remove the power assisted steering pump bracket.

Figure 57:

Figure 57

- Remove the dome headed nuts (1, Fig. 57) securing the crankcase breather.

Figure 58:

Figure 58

- Slacken the upper timing chain adjuster locknut and use tool JD 28 (1, Fig. 58) to slacken the top timing chain.
- Rotate the tool in a clockwise direction. Knock down the tabs at the camshaft sprockets and remove two bolts (2, Fig. 58) from each.
- Rotate the engine to gain access to the remaining bolts and remove.

CAUTION: Engine MUST NOT be rotated with the camshaft sprockets disconnected and the cylinder head in place.

- Draw the sprockets from the camshafts and slide the sprockets up the support brackets. Secure with a suitable rubber band, sprocket to sprocket.

NOTE: Mark 'fit' holes in the adjuster plates.

- Remove camshaft feed oil line banjo bolts from the rear of the cylinder head, the side of the cylinder block, and remove the oil line.
- Remove the fourteen cylinder head domed nuts and six nuts securing the front of the cylinder head working out from the center.
- Recover the two lifting brackets.
- Carefully lift the cylinder head assembly from the cylinder block.

CAUTION: As the valves in the fully open position protrude below the cylinder head joint face, the cylinder head MUST NOT be placed joint face downwards directly on a flat surface. Support the cylinder head on wooden blocks, one at each end.

- Remove and discard the gasket, clean the face of the block.

Figure 59:

Figure 59

- Knock back the locking tabs (1, Fig. 59) on the crankshaft pulley bolts.
- Remove the four bolts (2, Fig. 59) securing the pulley(s) to the torsional damper.
- Recover the locking ring and remove the outer pulleys.
- Remove the large bolt (3, Fig. 59) securing the torsional damper and recover the large plain washer (4, Fig. 59).
- Strike the damper with a hide mallet to break the taper, and remove it from the crankshaft.
- Remove the cone (5, Fig. 59) and extract the Woodruff key (6, Fig. 59) from the crankshaft.

Figure 60:

Figure 60

- Remove the bolts, nuts and spring washers (1, Fig. 60) securing the water pump.
- Remove the water pump and clean all traces of gasket from the mating faces.
- Unscrew the oil filter canister from the housing.
- Slacken the hose clips on the oil return pipe to the oil pan.
- Remove the four setscrews and spring washers securing the oil filter housing to the cylinder block.
- Pull the housing from the return pipe and clean all traces of gasket from the mating faces.



- Remove the two nuts and shakeproof washers securing the oil return pipe to the oil pan and remove the return pipe from the pan.
- Check the condition of the O-ring seal and renew it if necessary.
- Remove the setscrew, plain and spring washers and lift the distributor from the cylinder block.

- Remove the four nuts and spring washers, and all setscrews and spring washers securing the oil pan.
- Note the location of cooler pipe brackets-cars fitted with automatic transmission only.
- Remove the setscrews and special washers (2, Fig. 60) and carefully pry the timing chain cover from the engine. Recover the timing pointer (3, Fig. 60).

- Remove and discard the gasket and crankshaft oil seal.

Figure 62:

Figure 62

- Draw the distance piece (1, Fig. 62) from the crankshaft, check the condition of O-ring seal, and renew if necessary.
- Recover the oil thrower (2, Fig. 62) if fitted.
- Remove the setscrews securing the lower timing chain tensioner (3, Fig. 62) and chain guides (4, Fig. 62).
- Recover the conical filter (5, Fig. 62) behind the tensioner.
- Slacken the four setscrews and shakeproof washers (6, Fig. 62) securing the upper timing chain assembly.

NOTE: Do not remove the setscrews at this stage.

- Withdraw the crankshaft timing gear and chain assembly (7, Fig. 62). Carry out the overhaul.
- Remove the self locking nuts, bolts and washers and pull the suction pipe (8, Fig. 62) from the oil pan.
- Knock down the tabs, remove the self locking nut, washer and bolt, and pull the delivery pipe (9, Fig. 62) from the oil pan.
- Knock down the tabs and remove the three bolts (10, Fig. 62) securing the oil pump.
- Draw the oil pump clear and recover the drive coupling.
- Knock down the tab washer and remove the nut (11, Fig. 62) securing the distributor drive gear.
- Draw the gear and thrust washer from the shaft; remove the shaft and key.
- If necessary, remove the locating grub screw (12, Fig. 62) and drift the distributor drive shaft bush downwards from the cylinder block.

Figure 63:

Figure 63

-. Remove the special nuts (1, Fig. 63) securing the connecting rod caps; remove the caps together with the shell bearings.
- Pass the pistons up through the bores.
- Remove the crankshaft rear oil seal assembly cap screws.
- Remove and discard the oil seal.

Figure 64:

Figure 64

- Remove the main bearing bolts (1, Fig. 64) and washers, noting the position of the oil pipe brackets. Remove the bearing caps.
- Remove the two Allen screws securing the lower half of the rear oil seal.
- Pry out the seal.
- Remove the three Allen screws securing the upper half of the rear oil seal.
- Pry out the seal.
- Lift the crankshaft from the cylinder block.
- Recover the bearing shells.