Disassembly

1. Separate engine and transaxle.
2. Drain engine oil and coolant into suitable containers.
3. Remove engine front and rear side components.
4. Position No. 1 piston at TDC of compression stroke.
5. Loosen valve timing belt tensioner and set it to the ``free'' position. Remove idler pulley, then the crankshaft sprocket and valve timing belt.
6. Set injection timing belt tensioner to the ``free'' position and remove the belt.
7. Remove injection pump pulley, then the injection pump.
8. Remove oil pan and oil pump, then the rocker cover.

Fig. 1 Cylinder head bolt loosening sequence:

9. Remove cylinder head. Loosen bolts in several steps in sequence, Fig. 1.
10. Remove connecting rod caps and bearings, then push piston/connecting rod assemblies out towards the cylinder head side.
11. Remove main bearing caps and bearings, then the rear oil seal with retainer.
12. Remove crankshaft.

PISTON & ROD DISASSEMBLY
1. Remove piston rings with a ring expander.
2. Heat piston to approximately 140-158°F and tap out piston pin using a suitable drift.

CYLINDER HEAD DISASSEMBLY
1. Remove intake and exhaust manifolds.

Fig. 6 Camshaft bracket nut loosening sequence:

2. Remove both camshaft sprockets, then the camshaft bracket cap nuts. Loosen nuts in sequence, Fig. 6.
3. Remove camshaft and oil seals.
4. Remove valve lifters and lifter plates.
5. Remove valves, springs and related components using a suitable spring compressor. Keep all parts in order.

Fig. 7 Valve seal removal:

6. Remove valve seals, Fig. 7.