Disassembly

1. Remove gusset plate, power steering pulley and pump bracket from cylinder block.
2. Remove righthand side exhaust manifold insulator, then the exhaust manifold from cylinder block.
3. Remove righthand side engine mount bracket from cylinder block.
4. Remove knock sensor, then mount engine on a suitable engine stand.
5. Remove oil level gauge, A/C compressor bracket and idler pulley.
6. Remove engine mount bracket, then disconnect distributor connector and spark plug wires.
7. Remove distributor, engine hanger and plug hole cover.
8. Remove spark plugs and lefthand side exhaust manifold insulator.
9. Remove lefthand side exhaust manifold, then the coolant bypass hose

Fig. 5 Intake Manifold & Fuel Distribution Bolt Loosening Sequence. DOHC Engine:

10. Loosen intake manifold and fuel distribution pipe assembly mounting bolts in two or three steps in order shown in Fig. 5.
11. Remove coolant inlet pipe, oil cooler, oil filter assembly and lefthand side knock sensor.
12. Holding drive plate in position with tool No. 49 H011 102 or equivalent, remove crankshaft pulley lockbolt.
13. Remove crankshaft pulley, timing belt cover and No. 2 idler pulley.

Fig. 6 Aligning Matching Marks Of Cam Pulleys:

14. Turn crankshaft to align matching marks of the cam pulleys, Fig. 6.
15. Install crankshaft pulley lock bolts, then remove timing belt. Mark rotation direction on timing belt to ensure proper installation.
16. Remove No. 1 idler pulley, tensioner pulley and timing belt auto tensioner.
17. Using a suitable pulling tool, remove timing belt pulley and Woodruff key.
18. Remove cylinder head covers and seal plate.

Fig. 7 Removing Camshaft Pulleys:

19. Using an adjustable wrench to hold camshafts as shown in Fig. 7, remove camshaft pulley lock bolts.
20. Remove camshaft pulleys, then loosen front cap bolts of lefthand side cylinder head.

Fig. 8 Camshaft Cap Bolt Removal Sequence (Right):

Fig. 9 Camshaft Cap Bolt Removal Sequence (Left):

21. Remove camshaft cap bolts in two to three steps using sequence shown in Figs. 8 and 9.
22. Remove camshaft caps, camshaft oil seal, camshafts and rocker arms.
23. If necessary, remove Hydraulic Lash Adjusters (HLA) by hand.

Fig. 4 Cylinder Head Bolt Loosening Sequence. SOHC Engine:

24. Remove cylinder attaching bolts in two or three steps using sequence shown in Fig. 4.
25. Remove cylinder head gasket and timing belt idler pulley.

Fig. 10 Valve Keeper Removal:

26. Set a C-clamp against upper valve spring as shown in Fig. 10, then remove valve keepers.
27. Using needle nose pliers, remove valve seals if necessary.
28. Using holding tool No. 49 H011 102 or equivalent to hold drive plate into place, remove drive plate attaching bolts.
29. Remove backing plate, drive plate and adapter.
30. Remove oil pan mounting bolts, then use a screwdriver to pry oil pan away from cylinder block.
31. Remove oil strainer, then the water pump and thermostat assembly.
32. Remove oil pump, then using a screwdriver remove front and rear oil seals.
33. Remove O-rings from top of cylinder block.

Fig. 11 Measuring Connecting Rod Side Clearance:

34. Using a dial indicator, measure connecting rod side clearance as shown in Fig. 11. If clearance exceeds .016 inch, replace rod and cap.
35. Remove connecting rod caps, then the connecting rod bearings.
36. Using handle of a hammer, remove piston and connecting rod assembly through top of cylinder block.

Fig. 12 Checking Oscillation Of Piston & Connecting Rod:

37. Check oscillation torque of piston and connecting rod as shown in Fig. 12, if large end does not drop by its own wait, replace piston or piston pin.
38. Mark connecting rod direction for proper assembly.

Fig. 13 Piston Pin Removal Tool Assembly:

Fig. 14 Attaching Piston Pin Removal Tool To Piston:

39. Assemble special tools shown in Fig. 13 or their equivalents, then attach tools to piston as shown in Fig. 14.

Fig. 15 Pressing Pin Out Of Piston:

40. Mount piston and connecting rod assembly as shown in Fig. 15 and press piston pin out of piston.
41. Using piston ring expander, remove piston ring.

Fig. 16 Measuring Crankshaft Endplay:

42. Mount dial and measure crankshaft endplay as shown in Fig. 16. If endplay exceeds .0118 inch grind crankshaft and use an oversize thrust bearing or replace crankshaft and thrust bearing.

Fig. 17 Main Bearing Beam Bolt Removal Sequence:

43. Loosen main bearing beam bolts in two or three steps using sequence shown in Fig. 17.
44. Remove main bearing beam and crankshaft.