Engine Disassembly

1. Separate engine from transaxle, then remove clutch assembly using tool KV30101000, or equivalent.
2. If equipped, remove A/C compressor bracket and/or power steering pump bracket and pump idler pulley.
3. Remove air induction pipes on carbureted engines, then the exhaust manifold with cover and hot air duct.
4. Completely drain engine coolant and oil into suitable containers, then mount engine to a suitable workstand.
5. Remove drive belts, then the engine front cover.
6. Remove water pump pulley and crankshaft pulley.
7. Remove vacuum tube assembly for distributor and fuel vapor canister.
8. Remove alternator adjusting bar.
9. Remove distributor cap with high tension cables, then the distributor and spark plugs.
10. Remove intake manifold support, then the alternator.
11. Remove oil filter and oil pressure switch.
12. Remove carburetor and insulator if equipped, then the PCV valve hose.
13. Remove intake manifold assembly.
14. Remove oil pan and oil strainer, then the valve rocker cover.
15. Remove timing belt tensioner, then the camshaft sprocket and timing belt.

Fig. 1 Cylinder head bolt loosening sequence:

16. Remove cylinder head. Loosen bolts in sequence, Fig. 1. When removing cylinder head with engine installed in vehicle, rotate crankshaft until No. 1 piston is at TDC of compression stroke.
17. Remove oil pump and water pump assemblies.
18. Remove connecting rod 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.
19. Remove flywheel and end plate.
20. Remove main bearing caps and bearings. Loosen bolts in sequence, beginning with the outer bolts.
21. Remove rear oil seal retainer, then the crankshaft and bearings.
22. Remove baffle plate from cylinder block.

Piston & Rod Disassembly

1. Remove piston rings with a ring remover.
2. Press out piston pin. Keep disassembled parts in order.

Cylinder Head Disassembly

1. Remove rocker shaft assembly. Loosen bolts in sequence beginning with the outer bolts.
2. Remove camshaft, then the valves and valve components.