Engine Disassembly

1. Remove the following preliminary components from engine:
a. Exhaust manifold and fan pulley.
b. Water and fuel pumps.
c. Oil filter and intake manifold.
d. Alternator and distributor.
e. Thermostat and cover.
2. Mount engine onto a suitable work stand.

Fig. 1 Flywheel locking tool:

3. Using tool No. 49E301060 or equivalent, Fig. 1, lock flywheel. Using a suitable wrench, remove camshaft sprocket locknut and camshaft sprocket.

Fig. 2 Cylinder head bolt tightening sequence:

4. Remove cylinder head bolts in reverse sequence shown in Fig. 2, and remove cylinder head. Loosen cylinder head bolts a few turns at a time.
5. Using tool Nos. 490636100A and 490221222A or equivalents, remove valve assembly. Ensure valve assemblies are kept in sequence for each cylinder.
6. Using tool No. 49E301060 or equivalent, Fig. 1, lock flywheel and remove crankshaft pulley bolts, then the pulley.
7. Invert engine, then remove connecting rod cap bolts. Using a wood drift, push pistons out of cylinder block. Separate pistons from connecting rods using tool No. 49813040, or equivalent. Ensure disassembled pistons and piston rings, if removed, are kept in sequence for each cylinder.

Fig. 3 Removing main bearing cap:

8. Using tool No. 490221270B or equivalent, Fig. 3, remove main bearing caps from engine block. Remove crankshaft.