Engine Disassembly

1. Remove transaxle assembly with starter motor.
2. Remove clutch assembly, then mount engine to a suitable workstand.
3. Drain engine oil and coolant into a suitable container.
4. Remove distributor with high tension cable.
5. Remove air induction pipe bracket and EGR tube at EGR valve side.
6. Remove EGR and air induction pipes from exhaust manifold.
7. Remove exhaust manifold cover, then the manifold.
8. If equipped, remove A/C compressor bracket and/or power steering pump bracket.
9. Remove intake manifold with carburetor.
10. Loosen water pump pulley bolts, then remove alternator, alternator bracket and drive belt.
11. Remove oil filter, oil pump with gasket and the fuel pump with spacer.
12. Remove oil pan, gasket, seal, oil strainer and thermostat housing.
13. Remove flywheel or drive plate, then the rear plate.
14. Remove water pump and crankshaft pulleys, then the water pump assembly with gasket.

Fig. 2 Timing belt cover removal:

15. Remove upper and lower timing belt covers, Fig. 2, then the timing belt tensioner pulley and timing belt. Place a rotating direction mark on timing belt for assembly reference.
16. Remove jack shaft pulley, then the crankshaft sprocket with spacer.

Fig. 3 Cylinder head bolt loosening sequence:

17. Remove spark plugs, valve rocker cover and cylinder head bolts, then remove cylinder head. Remove cylinder head bolts in sequence, Fig. 3, in two or three steps.
18. Remove cylinder block front cover, then the jack shaft locating plate and jack shaft.
19. Remove connecting rod caps and bearings. Push piston and connecting rod assemblies out toward cylinder head surface. Numbers are stamped on connecting rods and caps corresponding to each cylinder. Care should be taken to keep all parts, including bearings, in correct order.

Fig. 4 Main bearing cap bolt loosening sequence:

20. Remove crankshaft oil seal retainer, then the main bearing caps with bearing. Loosen bolts in sequence, Fig. 4.
21. Remove crankshaft and bearings.




CYLINDER HEAD DISASSEMBLY




1. Remove camshaft sprocket, then the cylinder head cover.
2. Remove bolt stopper from Nos. 1 and 5 rocker shaft attaching bolts.
3. Remove rocker shaft assembly, then the camshaft.

Fig. 6 Valve removal. 1982-86:

4. Temporarily install rocker shaft and remove valves and valve components, Fig. 6.

Fig. 7 Valve oil seal removal. 1982-86:

5. Remove valve oil seals, Fig. 7.

Fig. 8 Rocker shaft assembly:

6. Remove rocker shaft from cylinder head, then remove springs and retainers from rocker shaft assembly, Fig. 8.