Disassemble

1. Remove the intake manifold. Intake Manifold

Exhaust Manifold Bolts:

2. Bend back the lock tabs, and remove the eight bolts securing each exhaust manifold, and withdraw the manifolds and gaskets.

Water Pump Bolts:

3. Remove the fifteen bolts and withdraw the water pump and joint washer.

NOTE: The water pump is not a serviceable item, in the event of bearing failure or severe corrosion to the pump impeller vanes, fit a new water pump assembly.

4. Remove the spark plug leads from the spark plugs and retaining clips, release the four screws and lift off the valve covers.

Rocker Shaft Bolts:

5. Remove the four rocker shaft retaining bolts and lift off the assembly.

Pushrods & Lifters:

6. Withdraw the pushrods and retain in the sequence removed.
7. Remove the hydraulic lifters and place to one side with their respective pushrods. If a lifter cannot be removed leave in position until the camshaft is removed.

Cylinder Head Bolts:

Cylinder Head Bolt Torque Sequence:

8. Evenly loosen the cylinder head bolts reversing the tightening order.
9. Before removing the heads mark them relative to the LH and RH side of the engine.
10. Lift off the cylinder heads and discard the gasket.
11. Remove the spark plugs.

NOTE: To ensure the flexible drive plate and ring gear assembly is re-assembled in their correct radial positions, scribe each component with an identification line to enable each part to be re-assembled in the correct relationship to one another.

Drive Plate Components:

12. Remove the four retaining bolts securing the flexible drive plate and ring gear assembly.
13. Withdraw the clamp ring, flexible drive plate, hub aligner and ring gear assembly.
14. Remove the six socket head bolts securing the crankshaft adaptor plate and shim to the crankshaft flange.
15. Withdraw the crankshaft adaptor plate and shim.
16. Inspect the ring gear assembly for distortion, cracks, chipped or badly worn teeth. If ring gear is in poor condition fit a complete new assembly.
17. Release the single nut securing the distributor clamp, remove the clamp and withdraw the distributor.
18. Remove the bolts from the oil pump cover.
19. Withdraw the oil pump cover.
20. Lift off the cover and remove the gasket.
21. Withdraw the oil pump gears.
22. Remove timing chain gear and camshaft. Timing Components
23. Withdraw the retaining bolts and remove the oil pan.
24. Remove the oil pan oil strainer.
25. Remove the connecting rod caps and retain them in sequence for reassembly. Be sure to number the caps/rods before removal.

Connecting Rod Tool:

26. Screw the guide bolts 605351 onto the connecting rods.

Fitting Piston & Rod:

27. Push the connecting rod and piston assembly up the cylinder bore and withdraw it from the top. Retain the connecting rod and piston assemblies in sequence with their respective caps.
28. Remove the guide bolts 605351 from the connecting rod.

Main Bearing Caps & Crankshaft:

29. Remove the main bearing caps and lower bearing shells and retain in sequence. It is important to keep them in pairs and mark them with the number of the respective journal until it is decided if the bearing shells are to be refitted,
30. Lift out the crankshaft and rear oil seal.