Engine Disassembly

1. Drain engine oil and coolant into a suitable container. Remove all engine accessories, brackets and mounts, camshaft cover, and timing belt cover.

Fig. 7 Crankshaft timing marks.:

Fig. 8 Camshaft timing marks.:

2. Rotate engine until mark on flywheel, Fig. 7, is aligned with mark on clutch housing, and mark on camshaft sprocket, Fig. 8, is aligned with upper edge of gasket surface on cylinder head.
3. Loosen bolts securing water pump to engine block and rotate pump counterclockwise to loosen belt.
4. Remove timing belt, bolts securing water pump and water pump. Do not rotate crankshaft or camshaft independently as engine damage may result.

Fig. 9 Cylinder head bolt torque sequence.:

5. Remove bolts securing cylinder head working from outside toward center in reverse of tightening sequence, Fig. 9.

Crankshaft & Cylinder Block Disassembly

1. Remove bolt securing crankshaft pulley, pulley and belt drive sprocket.
2. Remove oil pan, oil pump pickup and pickup tube.
3. Remove bolts securing oil pump, then the pump.
4. Using a suitable punch, mark connecting rods and caps with matching marks to aid assembly.
5. Remove connecting rod cap retaining nuts and remove cap and bearing.
6. Remove piston/connecting rod assemblies through cylinder head side of block, using a suitable drift. Keep pistons, connecting rods, rod caps and bearings in correct order.
7. Remove piston rings using a ring expander.
8. Remove piston pin retainers, piston pins and pistons from connecting rods.
9. Measure pistons approximately 5/8 inch from lower edge at 90° angle to piston axis.

Fig. 1 Cylinder bore checking dimensions:

10. Measure cylinder bores as shown in Fig. 1. If difference between measurements exceeds piston clearance specifications, new pistons must be fitted to bores.
11. Mark position of flywheel in relation to crankshaft and remove flywheel.
12. Remove bolts securing rear engine cover and remove rear cover and seal.
13. Note markings on main bearing caps, remove bolts securing main bearing caps, and remove caps along with lower main bearings.
14. Remove crankshaft from cylinder block and remove upper main bearings. Keep main bearings and bearing caps in correct order.

Cylinder Head Disassembly

Fig. 10 Camshaft bearing cap removal:

1. Diagonally loosen camshaft bearing caps 2 and 4, Fig. 10, and remove caps.
2. Diagonally remove camshaft bearing caps 1 and 3, Fig. 10, and remove caps.
3. Remove camshaft and followers, or hydraulic lifters, and keep in correct order.
4. Using suitable tool, compress valve springs and remove locks.
5. Remove valve springs, retainers and spring seats.
6. Remove valves and valve stem seals.
7. Press worn valve guides out of cylinder head from combustion chamber side.