Note: When disassembling, mark the removed parts that are suitable for further use so that when reassembling, they can be installed in their original locations and positions.
Separate the engine from the gearbox. Drain the oil from the oil pan. Remove the intake manifold and exhaust manifold. Remove the ignition distributor, generator and drive belt.
On vehicles with a carburetor fuel system, remove the fuel pump.
Remove the water pump. Remove the oil pan, then the crankshaft pulley and the camshaft drive belt protective covers. Loosen the toothed belt tension roller axle mounting nut and remove the belt.
Remove the cylinder head. Loosen the bolts securing the clutch housing to the flywheel and remove the housing together with the pressure plate. This releases the slave clutch disk. Remove the flywheel. Loosen the bolts and remove the holders of the front and rear crankshaft oil seals using two screwdrivers, resting them on the lugs. Remove the intermediate shaft from the cylinder block, having first removed the holder together with the oil seal. Place the cylinder block on a support. Make sure that there are marks on the connecting rod caps and the crankshaft main bearings.
If necessary, mark the connecting rods, crankshaft main bearing caps and the corresponding cylinders. Loosen the connecting rod bolt nuts and remove the connecting rod caps. Remove the pistons with connecting rods through the cylinders. Remove the connecting rod bearing shells and determine the degree of wear of the shells. If the shells can be used again, mark the shells to determine their position ("top", "bottom") and mark the corresponding connecting rods. Unclamp and remove the piston pin retaining rings with round-nose pliers (Fig. 2-2) and press out the pins with a mandrel.
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Check the axial free play of the crankshaft. Loosen the bolts securing the main bearing caps and remove the caps together with the lower liners. Remove the crankshaft from the bearing seats, and then the upper liners.
The main bearing caps are marked with numbers 1-5, indicating the order in which they were installed during engine assembly. If the main bearing shells are to be reused, both the lower and upper shells must be marked.
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