Disassembly

1. Disconnect battery ground cable, then remove engine oil dipstick.
2. Remove power steering pump bracket, then the exhaust manifold insulator.
3. Remove EGR pipe and, on turbo models, the turbocharger oil pipe.
4. Remove exhaust manifold assembly, then, on turbo models, the turbocharger bracket.
5. Remove coolant inlet pipe and bypass hose, then the engine hanger.
6. Remove alternator, strap and bracket, then the engine mount bracket.
7. Remove distributor with wires attached, then the spark plugs.
8. Remove thermostat and thermostat cover.
9. Remove intake manifold bracket, then the intake manifold assembly.
10. Remove oil filter and, on turbo models, the oil cooler.
11. Remove oil pressure switch and, on turbo models, the knock sensor.
12. Place ring gear brake tool 49E301060 or equivalent against flywheel, then remove crankshaft pulley and, except on 12 valve engine, the baffle plate.
13. Remove upper and lower timing belt covers, then the baffle plate.
14. Loosen tensioner lock bolt and remove timing belt tensioner and spring, then the timing belt and idler pulley. Using chalk, mark timing belt for direction of rotation and be careful not to get oil or grease on belt.
15. Remove camshaft pulley, using screwdriver to keep camshaft from turning.
16. Remove timing belt pulley, then the cylinder head cover and gasket.
17. Remove front and rear housings, then measure camshaft endplay and oil clearance of camshaft journals.

Fig. 1 Rocker Shaft Bolt Loosening Sequence:

18. Remove rocker arm, hydraulic lash adjuster and rocker shaft assembly, loosening bolts in two or three steps in proper sequence, Fig. 1.
19. Remove camshaft cap, then the camshaft.

Fig. 2 Cylinder Head Bolt Loosening Sequence:

20. Remove cylinder head bolts, loosening in two or three steps in proper order, Fig. 2, then the cylinder head and gasket.
21. Remove valve spring retainers, then the upper spring seats.
22. Remove valve springs, then the lower spring seats.
23. Using valve removal tool Nos. 490636100A and 49G030222 or equivalent, remove valves and valve seals.
24. On engines with manual transmission, remove clutch cover and clutch disc, then the flywheel using ring gear brake tool No. 49E301060 or equivalent.
25. On engines with automatic transmission, remove backing plate, then the drive plate and adapter using ring gear brake tool No. 49E301060 or equivalent.
26. On all engines, remove end plate, then the oil pan and strainer. Insert suitable tool between oil pan and baffle plate to separate them, being careful not to bend oil pan.
27. Remove baffle plate, then the rear cover and oil seal assembly with gasket.
28. Remove water pump and oil pump assembly.
29. Clean bearing, connecting rod and crankpin, then measure connecting rod side clearance and crankpin oil clearance.
30. Remove connecting rod caps, then the connecting rod bearings.

Fig. 3 Piston Pin Removal:

31. Remove connecting rods and pistons, then the piston rings. Remove piston pins from pistons, Fig. 3.
32. Clean bearings, main journals and caps and measure crankshaft endplay and oil clearance of main journals.
33. Remove main bearing caps, then the crankshaft.
34. On models with manual transaxle, use puller tool No. 491285071 or equivalent to remove pilot bearing from crankshaft.
35. Remove main bearings.