Engine Disassembly

1. Remove starter motor.
2. Separate engine from transmission:
a. On automatic transmission models, remove converter dust cover and remove bolts securing torque converter to drive plate.
b. Remove bolts securing transmission to engine and remove transmission.
c. On manual transmission models, remove clutch assembly from flywheel.
3. Remove alternator and alternator bracket.
4. Remove oil filter and oil pressure switch.
5. Completely drain engine oil and coolant by removing plugs from block.
6. Remove accessories and brackets from front of engine.
7. Remove crankshaft pulley using a suitable puller.
8. Disconnect and remove vacuum tube assembly for distributor and canister.
9. Disconnect high tension cables and remove distributor cap. Remove distributor.
10. Remove engine mounting brackets, compressor bracket, oil level gauge, and spark plugs.

Fig. 1 E.G.R. tube removal (Typical):

11. Remove E.G.R. tube and remove exhaust manifold assembly, Fig. 1.
12. Remove:
a. Power steering pump brackets and engine mounting bracket.
b. Water inlet.
c. A.B. valve with hose.
d. Carburetor and insulator.
e. Intake manifold as an assembly with E.G.R. valve, P.C.V. valve, water inlet and accelerator cable bracket.
13. Remove oil pump and drive spindle.
14. Remove oil pan and strainer.
15. Remove rocker cover.
16. Mark camshaft dowel pin position and remove camshaft sprocket.

Fig. 2 Cylinder head bolt loosening sequence:

17. Loosen cylinder head bolts in correct sequence, Fig. 2, remove bolts securing cylinder head to front cover, and remove cylinder head.

Fig. 3 Engine front side component removal:

18. Remove front cover, timing chain tensioner and chain guide, and timing chain. Refer to Fig. 3.
19. Remove oil thrower and oil pump drive gear, Fig. 3. Remove crankshaft gear using a suitable puller.
20. Remove connecting rod caps and bearings, and push connecting rod/piston combinations out towards cylinder head surface. Numbers are stamped on the connecting rods and caps corresponding to each cylinder. Care should be taken to keep all parts, including bearings in correct order.
21. Remove flywheel or drive plate and engine end plate.
22. Loosen main bearing cap bolts working from the outside toward the center main cap.

Fig. 4 Rear main bearing cap removal:

23. Remove main bearing caps with lower bearings. Refer to Fig. 4, to remove center and rear main bearing cap.
24. Remove rear oil seal, crankshaft, and upper bearings. Keep all bearings and main caps in correct order.
25. Remove baffle plate and steel net from engine block.