Disassembly

1. Remove engine mount and alternator bracket, then place engine on suitable stand.
2. Remove power steering and A/C idler pulleys and brackets.
3. Remove gusset plates, then the engine hanger.
4. Remove water inlet pipe and water bypass hose.
5. Remove distributor, then the EGR pipe.
6. Remove extension manifold, then the intake manifold assembly.
7. Remove exhaust manifold insulator, then the exhaust manifold assembly.
8. Remove engine oil dipstick and oil filter.
9. Place tool 49H011102 or equivalent against flywheel, then remove crankshaft pulley.
10. Remove baffle plate, then the left and right timing belt covers.
11. Remove upper idler pulley.
12. Mark direction of rotation on timing belt, then remove.
13. Remove timing belt tensioner pulley, then the lower idler pulley.
14. Remove timing belt auto tensioner.
15. Remove cylinder head cover, then the distributor spacer.
16. Remove oil pump drive gear cover, then the oil pump drive gear.
17. On models with automatic transmission, remove vacuum pipe.
18. On all models, remove blind cover and PCV valve.
19. Using tool 49H012010 or equivalent, loosen camshaft pulley lock bolts, then remove camshaft pulleys.
20. Remove seal plate.

Fig. 3 Rocker Shaft Bolt Loosening Sequence. SOHC Engine:

21. Loosen rocker arm and shaft assembly attaching bolts in two or three steps in proper sequence, Fig. 3, then remove rocker arm and shaft assembly together with bolts. Do not remove hydraulic lash adjuster unless necessary.
22. Remove camshaft oil seals.
23. Measure camshaft endplay, then remove thrust plate.
24. Remove camshaft, then the distributor and oil pump drive gear.

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

25. Loosen cylinder head bolts in two or three steps in proper sequence, Fig. 4, then remove bolts, cylinder head and gasket.
26. Remove valve retainers, then the upper spring seats.
27. Remove outer and inner valve springs, then the lower spring seats.
28. Using tools 490636100A and 49S120222, or equivalents, remove valves from cylinder head.
29. Remove valve seals.
30. Remove timing belt pulley.
31. Using suitable tools, remove clutch cover, clutch disc and flywheel, or backing plate drive plate and adapter.
32. Remove end plate, then the oil pan attaching bolts and oil pan. Insert a suitable tool between oil pan and cylinder block to separate them, being careful not to bend oil pan.
33. Remove oil strainer, oil pump, and the oil pump drive shaft.
34. Remove water pump, then the thermostat assembly.
35. Remove front cover and front oil seal, then the rear cover and rear oil seal.
36. Clean bearing, connecting rod and crankpin, then measure connecting rod side clearance and crankpin oil clearance.
37. Remove connecting rod caps, connecting rod and piston assemblies and the connecting rod bearings.
38. Hold piston and connecting rod assembly sideways and raise connecting rod. If large end does not drop by its own weight, replace piston or piston pin.
39. Using suitable tools, remove piston pins. If pin can be removed with a force of less than 1100 lbs., replace piston pin or connecting rod.
40. Clean bearings, main journals and caps, then measure crankshaft endplay and oil clearances of main journals.
41. Remove main bearing caps, crankshaft and main bearings.
42. Remove oil baffle plate.