Engine Disassembly

Fig. 1 Crankshaft pulley removal:

1. Drain engine oil.
2. Using Flywheel Holder 09924-17810, or equivalent, remove clutch cover attaching bolts, then clutch cover and disc.
3. Disconnect spark plug wires and vacuum hoses noting direction for installation, then remove distributor assembly.
4. Remove fuel pump attaching bolts, then fuel pump and rod.
5. Remove crankshaft pulley attaching bolts, then crankshaft pulley, Fig. 1. It is not necessary to remove crankshaft pulley center bolt.
6. Remove timing belt cover attaching bolts, then timing belt cover.

Fig. 7 Timing belt removal:

7. Loosen tensioner bolt and stud, then remove timing belt from crankshaft timing belt pulley by pushing upward on tensioner with finger, Fig. 7.
8. Remove timing belt tensioner, tensioner plate and spring.

Fig. 8 Timing belt sprocket removal:

9. Using Camshaft Holder Tool 09917-68210, or equivalent, remove camshaft timing belt pulley, Fig. 8.

Fig. 9 Removing crankshaft timing belt pulley:

*** UPDATED BY TSB-ST-017-6 AUGUST, 1990.
10. Using Flywheel Holder 09924-17810, or equivalent, so that crankshaft will not rotate, remove crankshaft timing belt pulley bolt, pulley and belt guide, Fig. 9.
11. Remove crankshaft timing belt pulley key from crankshaft.
12. Remove water pump attaching bolts, then water pump.
13. Remove exhaust manifold shield attaching bolts, then shield.
14. Remove exhaust manifold attaching bolts, then exhaust manifold.
15. Remove oil filter.
16. Remove hoses from water pump inlet pipe.
17. Disconnect positive PCV hose from valve cover.
18. Remove intake manifold attaching bolts, then intake and carburetor as an assembly.
19. Remove water pump inlet pipe attaching bolts, then inlet pipe.
20. Remove valve cover attaching bolts, then valve cover.
21. Loosen all valve adjusting screws and rocker arm shaft bolts, then pull out rocker arm shaft while separating rocker arms and springs.
22. Remove camshaft from rear of engine.
Note: Before removing the cylinder head remove pooled oil from the top of the head to prevent oil from going into the engine water jackets. This will prevent contamination of the engine coolant.
23. Remove cylinder head attaching bolts, then cylinder head.
24. Using a suitable spring compressor, compress valve springs and remove valve locks, then spring and valve.
25. Using a suitable screwdriver, remove valve stem oil seals from valve guides, then valve spring seats. Do not reuse oil seals after removal.
26. Using Flywheel Holder Tool 09924-17810, or equivalent, remove flywheel attaching bolts, then flywheel.
27. Remove oil dipstick attaching bolt, then oil dipstick.
28. Remove oil pan attaching bolts, then oil pan.
29. Remove oil pump strainer attaching bolts, then oil pump strainer.
30. Remove connecting rod bearing cap bolts, then bearing caps noting direction for installation.
31. Decarbon top of each cylinder bore, before removing pistons from cylinder.
32. Remove piston and connecting rod assemblies out through top of cylinder bore. Before removing pistons, scribe cylinder number on top of pistons and ensure each bearing cap matches rod and piston assemblies for installation.
33. Remove oil pump attaching bolts, then oil pump and pump rotor plate.
34. Remove oil seal housing attaching bolts, then oil seal housing.
35. Remove crankshaft bearing cap bolts, then bearing caps noting direction for installation.
36. Remove crankshaft from cylinder block.