Disassembly

1. Remove the distributor to spark plug wires from the spark plugs.

NOTE: Mark the location of each distributor to spark plug wire for proper installation.





2. Unscrew the three distributor cap screws.

NOTE: The distributor cap screws are not removable from the distributor cap.

3. Remove the distributor cap with the distributor to spark plug wires still attached to their respective terminals.





4. Remove the EGR valve to exhaust manifold tube from the EGR valve and the rear exhaust manifold.





5. Disconnect the positive crankcase ventilation (PCV) valve from the rear valve cover.





6. Disconnect the fast idle control (FIC) solenoid electrical connector.
7. Disconnect the idle air control (IAC) solenoid electrical connector.
8. Disconnect the coolant hose from the idle air control-fast idle control (IAC-FIC) assembly.
9. Disconnect the fuel tubes.





10. Disconnect the fuel pressure regulator-to-upper intake manifold vacuum hose from the fuel pressure regulator.





11. Disconnect the coolant hose from the side of the throttle body.





12. Remove the two main wiring harness bracket-to-upper intake manifold bolts from the front of the upper intake manifold and position the harness out of the way.





13. Disconnect the rear breather hose from the rear valve cover.
14. Remove the crossover breather tube bracket bolt and the crossover breather tube from the upper engine front cover.





15. Remove the two front breather tube bracket-to-upper intake manifold bolts.
16. Disconnect the front breather hose from the front valve cover.





17. Remove the five Allen head upper intake manifold to lower intake manifold bolts.





18. Remove the upper intake manifold. Discard the intake manifold upper gasket.





19. Remove the distributor hold-down bolt.
20. Remove the distributor. Discard the distributor base gasket.
21. Disconnect the six fuel injector electrical connectors.
22. Remove the four Allen head fuel injection supply manifold bolts.
23. Remove the fuel injection supply manifold, fuel injector spacers, fuel injector insulators, and fuel injectors as an assembly.





24. Remove the water bypass hose from between the thermostat housing and the water hose connection.
25. Remove the upper engine front cover bolt which is attached to the water hose connection.





26. Remove the four Allen head upper intake manifold to lower intake manifold bolts and the four upper intake manifold to lower intake manifold nuts from the lower intake manifold in two steps in the sequence shown.
27. Remove the lower intake manifold washers.
28. Remove the lower intake manifold and intake manifold gaskets. Discard the intake manifold gaskets.





29. Remove the two thermostat housing bolts.





30. Remove the two coolant crossover tube bolts.
31. Remove the thermostat housing and the coolant crossover tube from the engine.





32. Remove the knock sensor bolt and the knock sensor (KS).





33. Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley while removing the water pump pulley bolts.





34. Use Strap Wrench D85L-6000-A or equivalent to hold the crankshaft pulley while removing the crankshaft pulley bolt.





35. Use Crankshaft Damper Remover T58P-6316-D Forcing Screw and Tip (part of T74P-6700-A) with Bolt Set - Crankshaft Damper Removal T92G-6701-AH to pull the crankshaft pulley off the front of the crankshaft.





36. Remove the inner timing belt guide.
37. Remove the eight upper engine front cover bolts and the upper engine front cover.





38. Remove the five lower engine front cover bolts and the lower engine front cover.





39. If the timing belt is to be reused, mark the direction of rotation on the timing belt.

NOTE: The directional arrow is necessary to ensure that the timing belt can be reinstalled in the same direction.





40. Remove the timing belt tensioner nut, timing belt tensioner, and timing belt tensioner spring.
41. Remove the timing belt.





42. Use Cam Sprocket Holding/Removing Tool T74P-6256-B to hold the camshaft sprocket while removing the camshaft sprocket retaining bolt and camshaft sprocket washer.
43. Remove the camshaft sprockets from both camshafts.
44. Remove the four seal plate bolts and the seal plate.
45. Remove the two nuts and one bolt securing the rear exhaust manifold crossover tube to the front exhaust manifold. Discard the gasket.
46. Remove the transmission fluid level indicator tube heat shield.








47. Loosen the exhaust manifold nuts in two steps in the sequence shown.
48. Remove the exhaust manifolds from the cylinder heads. Discard the exhaust manifold gaskets.





49. Remove the two oil level indicator tube bracket bolts and the oil level indicator tube.





50. Remove the 18 valve cover screws and both valve covers. Discard the valve cover gaskets.
51. Loosen the rocker arm shaft bolts in two steps.

CAUTION: Loosening the rocker arm shaft bolts in one step may bend the rocker arm shaft.

52. Remove the rocker arm shaft and rocker arm assemblies from the rocker arm shaft supports.

NOTE: Mark the location of the rocker arm shafts to ease installation.





53. Secure the valve tappets to the rocker arm shaft support with mechanic's wire.

NOTE: Use mechanic's wire to hold the valve tappet in the rocker arm shaft support during removal.

54. Remove the rocker arm shaft supports and set them with their respective rocker arm shaft assemblies.





55. Loosen the cylinder head bolts in two steps in the sequence shown.
56. Remove the cylinder heads from the cylinder block. Discard the cylinder head bolts and head gaskets.





57. Remove the crankshaft sprocket crankshaft keys, and the inner and outer timing belt guides from the front of the crankshaft.





58. Remove the six water pump bolts and the water pump.

NOTE: Mark the location of the water pump stud/bolt for ease of installation.

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(Part 2 Of 2):

59. Remove the three oil filter adapter bolts and the oil filter adapter. Discard the oil filter adapter O-rings.





60. Remove the 18 oil pan bolts in the sequence shown.
61. Remove the oil pan and oil pan seals from the cylinder block. Discard the oil pan seals.





62. Remove the two oil pump screen cover and tube bolts, oil pump screen cover and tube, and oil pump inlet tube gasket. Discard the oil pump inlet tube gasket.





63. Remove the six oil pump bolts.
64. Remove the oil pump and oil pump gasket from the cylinder block. Discard the oil pump gasket.





65. Remove the four crankshaft rear main oil seed cover bolts.
66. Remove the crankshaft rear main oil seal cover and crankshaft rear main cover gasket from the cylinder block. Discard the crankshaft rear main cover gasket.
67. Turn the crankshaft until the piston to be removed is at Bottom Dead Center (BDC).
68. Remove the carbon from the upper portion of the cylinder bore. If a ridge can be felt or seen at the top of the bore, it must be removed. If necessary, install the Cylinder Ridge Reamer T64L-6011-EA in the cylinder bore and remove the ridge.

NOTE: Following directions of the ridge reamer manufacturer, remove the ridge until the bore is straight to the top edge of the cylinder.





69. Repeat the following four steps for each of the piston and connecting rod assemblies:
a. Remove the 12 connecting rod nuts.
b. Remove the connecting rod cap and the lower half of the connecting rod bearing.

NOTE: The connecting rod caps and connecting rods are marked with numbers designating to which connecting rod each cap belongs. These numbers also correspond with piston-to-cylinder location.

c. Use a hammer handle or piece of wood to tap the piston up out of the cylinder. Remove the piston and the upper half of the connecting rod bearing from its cylinder.
d. Place the piston and connecting rod assemblies with their respective connecting rod caps to ease installation.





70. Loosen the eight crankshaft main bearing cap bolts in two steps in the sequence shown.
71. Remove the crankshaft main bearing cap and the lower crankshaft main bearings.





72. Carefully lift the crankshaft out of the cylinder block.

CAUTION: The crankshaft is heavy. Be careful not to drop it when removing it from the cylinder block.

73. Remove the upper crankshaft main bearings from the cylinder block.