Engine Disassembly

1. Remove starter motor.
2. Separate transmission from engine:
a. On automatic transmission models, remove converter dust cover and remove bolts securing torque converter to drive plate.
b. Remove bolts securing transmission and remove transmission.
3. Remove clutch assembly from flywheel.
4. Remove auxiliary cooling fan and duct, where equipped.
5. Remove alternator and alternator bracket.
6. Remove R.H. engine mount.
7. Remove oil pressure switch.
8. Completely drain engine oil and coolant into a suitable container, by removing drain plugs.
9. Disconnect and remove following components:
a. Distributor cap and high tension cables.
b. Distributor assembly.
c. Hoses connected to engine.
10. Remove fan, fan coupling and fan pulley.
11. Remove alternator adjusting bar and pulley bracket with idler pulley for power steering if so equipped.
12. Remove intake manifold as an assembly with fuel pipes and air regulator.
a. Disconnect hose between throttle chamber and rocker cover at rocker cover.
b. Disconnect pipe between heater housing and water inlet at water inlet.
c. Remove bolt securing water pipe and fuel pipe to cylinder head.
d. Remove tube connecting heater housing to thermostat housing.

Fig. 2 Intake manifold & fuel injection assembly (Typical):

e. Remove bolts securing intake manifold to cylinder head and remove intake manifold assembly, Fig. 2.
f. Remove P.C.V. hose, sub-heat shield plate, and E.G.R. tube if so equipped.
13. Remove crankshaft pulley, using suitable puller.
14. Remove exhaust manifold.
15. Remove thermostat housing and water pump.
16. Remove air conditioning compressor bracket where equipped.
17. Remove L.H. engine mount.
18. Remove water inlet and water pipes.
19. Remove spark plugs and oil gauge.

Fig. 3 Oil pump replacement:

20. Remove oil pump and oil pump drive spindle, Fig. 3.
21. Remove oil pan and oil strainer.
22. Remove rocker cover.
23. Lock camshaft and remove camshaft bolt.

Fig. 4 Camshaft sprocket removal:

24. Remove camshaft sprocket, Fig. 4, and slowly lower timing chain. Before removing camshaft sprocket be sure to mark position of camshaft dowel pin in camshaft sprocket. This step is extremely important to insure proper installation of timing chain during assembly.

Fig. 5 Cylinder head bolt loosening sequence:

25. Remove bolts securing cylinder head to front cover and loosen cylinder head bolts in sequence, Fig. 5, and remove cylinder head.

Fig. 6 Crankshaft sprocket removal:

26. Remove front cover, timing chain, chain tensioner and guides, oil thrower, oil pump drive gear and crankshaft sprocket, Fig. 6.
27. Lock crankshaft and remove flywheel or drive plate.
28. Remove connecting rod bearing caps and bearings. Push piston/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. 7 Rear main bearing cap removal:

29. Loosen main bearing cap bolts in three stages working from the outside toward the center cap. Remove main bearing caps and lower bearings, keeping them in correct order. Use tool, Fig. 7, to remove center and rear main caps.

Fig. 8 Rear oil seal removal:

30. Remove rear main seal, Fig. 8, and remove crankshaft.
31. Remove upper main bearings, keeping them in correct order.

Fig. 9 Baffle plate & steel net replacement:

32. Remove baffle plate and steel net from cylinder block, Fig. 9.

PISTON & ROD DISASSEMBLY

1. Remove piston rings with a ring remover.
2. Press piston pin.

Fig. 10 Rocker arm assembly removal:

CYLINDER HEAD DISASSEMBLY

1. Remove valve rocker springs. Loosen valve rocker pivot locknut and remove rocker arm by pressing valve spring downward, Fig. 10.
2. Remove locating plate, and the camshaft. Be careful not to damage camshaft bearings and cam lobes.

Fig. 11 Valve removal:

Fig. 12 Valve components:

3. Remove valves, Figs. 11 and 12.