Disassembly

Fig. 38 Auxiliary Engine Component Removal & Installation Sequence:

During the disassembly procedure, code or arrange all identical parts (such as pistons, piston rings, connecting rods and valve springs) so they can be reinstalled in their original positions.
1. Drain engine oil, then remove auxiliary components from cylinder block in the order shown in Fig. 38.
2. Remove timing belt, refer to TIMING BELT.
3. Remove camshafts, refer to CAMSHAFT & HYDRAULIC LASH ADJUSTERS.
4. Mark hydraulic lash adjusters with a felt pen so that they can be installed in their original positions.
5. Using Valve Spring Compressor tool No. 49-0636-100A and Valve Compressor Foot tool No. 49-B012-0A2 or equivalent, compress the spring and remove the valve keepers.
6. Using Valve Seal Removal tool No. 49-S120-170 or equivalent, remove valve seals from cylinder head.

Fig. 39 External Engine Component Removal & Installation Sequence:

Fig. 37 Flywheel Loosening & Tightening Sequence:

7. Remove external engine block components in the order shown in Fig. 39, noting the following:
a. On manual transaxle models, remove clutch cover retaining bolts by loosening in two or three steps.
b. Using Flywheel Holding tool No. 49-E011-1A0 or equivalent, remove flywheel retaining bolts in the sequence shown in Fig. 37.
c. On all models, remove the water pipe and thermostat housing from the engine block as an assembly.
d. Using Knock Sensor Wrench tool No. 49-H018-001 or equivalent, remove knock sensor.

Fig. 40 Internal Engine Component Locations:

Fig. 41 Cylinder Block Retaining Bolt Loosening Sequence:

Fig. 42 Bolt Installation For Separation Of Cylinder Block Halves:

8. Remove engine block internal components in the order shown in Fig. 40, noting the following:
a. Prior to removing connecting rod caps, measure the connecting rod side clearance.
b. Prior to removing connecting rods, measure the connecting rod bearing oil clearance using plastigage.
c. Using the wooden handle of a hammer, push the piston through the top of the cylinder block.
d. Mark the connecting rod direction for proper reassembly. Prior to disassembling the piston and connecting rod, check the oscillation torque by holding the piston in one hand, then raise the connecting rod upward. Allow the connecting rod to drop under its own weight. If the rod does not drop, replace the piston or piston pin as necessary.
e. Prior to removing crankshaft, measure the crankshaft endplay.
f. Loosen the cylinder block bolts and crankshaft cap bolts in two or three steps in the order shown in Fig. 41.
g. Install two M8x1.25, 4.72 inch bolts as shown in Fig. 42, then turn the bolts to separate the lower cylinder block from the upper block. Do not use scraping tool to separate the block. Tap block with plastic hammer, if necessary.