Part 1

Draining Fluids and Oil Filter Removal




1. Remove the oil pan drain plug and allow the engine oil to drain into a suitable container.




2. Remove the oil filter (if applicable).
3. Discard the oil filter (if applicable).




4. Remove both the engine block coolant drain hole plugs and allow the coolant to drain into a suitable container.

Engine Flywheel Removal




1. Remove the engine flywheel bolts.
2. Remove the engine flywheel (automatic transmission), if applicable.
3. Remove the engine flywheel (manual transmission),if applicable.

Important: If replacing the engine flywheel (manual transmission), then NEW flywheel weights must be installed into the NEW engine flywheel in the same location as the old flywheel weights in the old engine flywheel.




4. Note the position of any flywheel weights for assembly (if applicable).

Clutch Pilot Bearing Removal

Tools Required
- J 43276 Clutch Pilot Bearing Remover

Caution: Wear safety glasses in order to avoid eye damage.

Notice: When using the J 43276 Clutch Pilot Bearing Remover always secure the J 43276-1 Clutch Pilot Bearing Remover tool body using a wrench. Do not allow the J 43276-1 Clutch Pilot Bearing Remover tool body to rotate. Failing to do so will cause damage to the J 43276-1 Clutch Pilot Bearing Remover tool body.




1. Remove the clutch pilot bearing using the J 43276.
1. Install the J 43276-1 tool body into the clutch pilot bearing.
2. Using a wrench secure the J 43276-1 tool body.
3. Insert the J 43276-2 forcing screw into the J 43276-1 tool body.
4. Rotate the J 43276-2 forcing screw clockwise into the J 43276-1 tool body until the clutch pilot bearing is completely removed from the crankshaft.
5. Rotate the J 43276-2 forcing screw counterclockwise to remove the J 43276-2 forcing screw from the J 43276-1 tool body.
6. Remove the J 43276-1 tool body from the clutch pilot bearing.
2. Discard the clutch pilot bearing.

Exhaust Manifold Removal (Left)

Notice: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged.




1. Remove the spark plug wires from the spark plugs.
1. Rotate the spark plug wire boot one half turn.
2. Pull outward on the spark plug wire boot to release from the sparkplug.
2. Remove the spark plug wire retainers from the spark plug wire support.
3. Remove the exhaust manifold bolts and stud.
4. Remove the spark plug wire shields.
5. Remove the exhaust manifold.




6. Remove and discard the exhaust manifold gaskets.

Exhaust Manifold Removal (Right)

Notice: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged.




1. Remove the spark plug wires from the spark plugs.
1. Rotate the spark plug wire boot one half turn.
2. Pull outward on the spark plug wire boot to release from the sparkplug.
2. Remove the exhaust manifold bolts.
3. Remove the spark plug wire shields.
4. Remove the exhaust manifold.




5. Remove and discard the exhaust manifold gasket.

Oil Level Indicator and Tube Removal




1. Remove the oil level indicator from the oil level indicator tube.




2. Remove the oil level indicator tube bolt.
3. Remove the oil level indicator tube from the engine block.

Water Pump Removal




1. Remove the bolts and the fan and water pump pulley.




2. Remove the clamps and the water pump inlet hose.




3. Remove the water pump bolts.
4. Remove the water pump.
5. Remove the water pump gaskets.
6. Discard the water pump gaskets.

Crankshaft Balancer Removal

Tools Required
- J 23523-F Balancer Remover and Installer




1. Remove the crankshaft balancer bolt and washer.




2. Remove the bolts and the crankshaft pulley.

Notice: To prevent damage to the end of the crankshaft when using a crankshaft balancer removal tool install a bolt in the crankshaft. Use a shorter bolt with the same threads as the crankshaft balancer bolt. This bolt will allow a place for the tool to push against. The shorter bolt is to keep from going past the threads in the crankshaft and damaging the crankshaft threads.





3. Use the J 23523-F in order to remove the crankshaft balancer.
1. Install the J 23523-F plate and bolts.
Tighten the bolts to 25 N.m (18 lb ft).
2. Install the J 23523-F forcing screw.
3. Rotate the J 23523-F forcing screw clockwise in order to remove the crankshaft balancer.
4. Remove the J 23523-F from the crankshaft balancer.




5. Note the position of any front groove pins (crankshaft balancer) (if applicable).

Valve Rocker Arm Cover Removal (Left)




1. Remove the valve rocker arm cover bolts.
2. Remove the valve rocker arm cover bolt grommets.
3. Discard the valve rocker arm cover bolt grommets.




4. Remove the valve rocker arm cover.




5. Remove the valve rocker arm cover gasket.
6. Discard the valve rocker arm cover gasket.

Valve Rocker Arm Cover Removal (Right)




1. Remove the valve rocker arm cover bolts.
2. Remove the valve rocker arm cover bolt grommets.
3. Discard the valve rocker arm cover bolt grommets.




4. Remove the valve rocker arm cover.




5. Remove the valve rocker arm cover gasket.
6. Discard the valve rocker arm cover gasket.

Distributor Removal




1. Remove the ignition coil wire harness from the ignition coil and distributor cap.




2. Remove the distributor clamp bolt.
3. Remove the distributor clamp.
4. Remove the distributor.

Intake Manifold Removal




1. Remove the evaporative emission (EVAP) canister purge solenoid valve harness.
1. Push the quick disconnect clip and hold in place.
2. Pull outward on the harness elbow.




2. Remove the lower intake manifold bolts.

Important:
The in take manifold may be removed as an assembly. Do not remove the specific intake manifold components unless component service is required.
Do not allow dirt or debris to enter the fuel system. Ensure that the ends of the fuel system are properly sealed.
Do not disassemble the Central Sequential Fuel Injection (SF1) unit,unless service is required.

3. Remove the intake manifold assembly.
4. Remove and discard the lower intake manifold gaskets.

Valve Rocker Arm and Push Rod Removal

Important: Mark, sort, and organize all the components for assembly.




1. Remove the following components from the cylinder head:
1. The valve rocker arm nuts
2. The valve rocker arm balls
3. The valve rocker arms




2. Remove the valve rocker arm studs.




3. Remove the valve pushrods.

Cylinder Head Removal (Left)




1. Remove the engine coolant temperature sensor (if applicable).




2. Remove the engine coolant temperature gauge sensor (if applicable).




3. Remove the spark plugs.




4. Remove the bolts and the spark plug wire support.




5. Remove the cylinder head bolts.

Notice: After removal, place the cylinder head on two wood blocks to prevent damage.




6. Remove the cylinder head.




7. Remove and discard the cylinder head gasket.




8. Remove the dowel pins (cylinder head locator) (if required).

Cylinder Head Removal (Right)




1. Remove the spark plugs.




2. Remove the bolts and the spark plug wire support.




3. Remove the cylinder head bolts.

Notice: After removal, place the cylinder head on two wood blocks to prevent damage.




4. Remove the cylinder head.




5. Remove and discard the cylinder head gasket.




6. Remove the dowel pins (cylinder head locator) (if required).

Valve Lifter Removal

Tools Required
- J 3049-A Valve Lifter Remover

Important: Place the components in a rack so that the components can be reinstalled to their original location.




1. Remove the bolts and valve lifter pushrod guide.

Important: Place the valve lifters in the rack in the upright position in order to maintain the oil inside the valve lifters.




2. Remove the valve lifters.

Important: Some valve lifters may be stuck in the valve lifter bores because of gum or varnish deposits and may require the use of J 3049-A for removal.




3. Use the J 3049-A in order to remove the stuck valve lifters.