#### DISASSEMBLY

The engine disassembly instructions following assume that you have the engine mounted on an engine stand. If not, it is easiest to disassemble the engine on a bench or the floor with it resting on the bellhousing or transmission mounting surface. You must be able to access the connecting rod fasteners and turn the crankshaft during disassembly. Also, all engine covers (timing, front, side, oil pan, whatever) should have already been removed. Engines which are seized or locked up may not be able to be completely disassembled, and a core (salvage yard) engine should be purchased.

If not done during the cylinder head removal, remove the timing chain/belt and/or gear/sprocket assembly. Remove the oil pick-up and pump assembly and, if necessary, the pump drive. If equipped, remove any balance or auxiliary shafts. If necessary, remove the cylinder ridge from the top of the bore. See the cylinder ridge removal procedure earlier in this section.

Rotate the engine over so that the crankshaft is exposed. Use a number punch or scribe and mark each connecting rod with its respective cylinder number. The cylinder closest to the front of the engine is always number 1. However, depending on the engine placement, the front of the engine could either be the flywheel or damper/pulley end. Generally the front of the engine faces the front of the vehicle. Use a number punch or scribe and also mark the main bearing caps from front to rear with the front most cap being number 1 (if there are five caps, mark them 1 through 5, front to rear).

Fig. 1: Place rubber hose over the connecting rod studs to protect the crankshaft and cylinder bores from damage

WARNING
Take special care when pushing the connecting rod up from the crankshaft because the sharp threads of the rod bolts/studs will score the crankshaft journal. Insure that special plastic caps are installed over them, or cut two pieces of rubber hose to do the same.

Fig. 2: Carefully tap the piston out of the bore using a wooden dowel

Again, rotate the engine, this time to position the number one cylinder bore (head surface) up. Turn the crankshaft until the number one piston is at the bottom of its travel, this should allow the maximum access to its connecting rod. Remove the number one connecting rods fasteners and cap and place two lengths of rubber hose over the rod bolts/studs to protect the crankshaft from damage. Using a sturdy wooden dowel and a hammer, push the connecting rod up about 1 inch (25mm) from the crankshaft and remove the upper bearing insert. Continue pushing or tapping the connecting rod up until the piston rings are out of the cylinder bore. Remove the piston and rod by hand, put the upper half of the bearing insert back into the rod, install the cap with its bearing insert installed, and hand-tighten the cap fasteners. If the parts are kept in order in this manner, they will not get lost and you will be able to tell which bearings came form what cylinder if any problems are discovered and diagnosis is necessary. Remove all the other piston assemblies in the same manner. On V-style engines, remove all of the pistons from one bank, then reposition the engine with the other cylinder bank head surface up, and remove that banks piston assemblies.

The only remaining component in the engine block should now be the crankshaft. Loosen the main bearing caps evenly until the fasteners can be turned by hand, then remove them and the caps. Remove the crankshaft from the engine block. Thoroughly clean all of the components.