Disassembly

1. Place engine in suitable workstand.
2. Remove oil dipstick and oil filter, then drain crankcase oil.
3. Disconnect starter wiring, then remove three starter attaching bolts and the starter.
4. Remove transmission to engine attaching bolts and nuts and the transmission.
5. Mark relationship of clutch pressure plate to flywheel for proper assembly.
6. Remove clutch to flywheel attaching bolts and the clutch.
7. Disconnect vacuum hose at distributor.
8. Disconnect spark plug wires at plugs, then remove distributor holding clamp and the distributor.
9. Remove crankcase breather attaching bolt, then the breather and gasket.
10. Remove bolts, washers and nuts securing alternator to mounting brackets, then remove alternator and drive belt.
11. Remove alternator mounting bracket to engine attaching bolts and washer, then the bracket.
12. Disconnect air hose at check valve, then remove air pump attaching bolts and washers and remove air pump with hoses attached.
13. Remove check valve.
14. Disconnect EGR tube from carburetor base and exhaust manifold and remove spacer and gasket.
15. Remove EGR tube to valve attaching bolts and washers and separate tube and valve.
16. Disconnect vacuum hose at EGR valve, then remove EGR valve attaching bolts and washers and the valve.
17. Remove EGR base attaching bolts and washers, then the base and gasket.
18. Disconnect coolant hoses at thermostat housing.
19. Remove coolant pipe to water pump attaching bolts and the pipe.
20. Remove water pump attaching bolts and washers, then the pump and gasket.
21. Remove thermostat housing attaching bolts and washers, then the housing and gasket.
22. Remove timing bolt cover attaching bolts and washers and the cover.
23. Install tool A 60360 or equivalent on flywheel to inhibit engine rotation.

Fig. 1 Exploded view of timing belt assembly:

24. Remove camshaft sprocket bolt, Fig. 1, and the auxiliary shaft sprocket bolt.
25. Using suitable tool, remove crankshaft pulley.
26. Remove nut, washers and spacer, then press bracket against tensioner in right engine mount and remove pulley and timing belt.
27. Remove tensioner support bracket from stud and remove stud.
28. Remove three right engine mount attaching bolts and the mount.
29. Remove camshaft sprocket, auxiliary shaft sprocket, crankshaft pulley and the crankshaft sprocket.
30. Remove bolts and nuts attaching belt shields, then the shields.
31. Disconnect fuel pump line at carburetor, leaving filter and fuel pump lines attached to pump.
32. Remove fuel pump, ensuring that actuating rod is removed.
33. Remove carburetor.
34. Remove cylinder head, with manifolds and camshaft housing, by removing cylinder head attaching nuts and bolts. Remove gasket.
35. Remove auxiliary shaft cover and seal and the auxiliary shaft.
36. Remove six flywheel attaching bolts and washer plate, then the flywheel.
37. Invert engine on stand and remove oil pan attaching bolts, then the pan and gasket.

Fig. 2 Lower crankcase:

38. Remove six flywheel end cover plate attaching bolts and lock washers, then the end cover plate and gasket, Fig. 2.
39. Remove five timing gear end cover plate attaching bolts and lock washers, then the plate and gasket.
40. Remove three oil pump assembly attaching bolts and lockwashers, then the pump with oil pickup tube and gasket.
41. Remove oil return pipe attaching bolt and the pipe.
42. Remove connecting rod caps, complete with bearing inserts, from crankshaft.
43. Remove four piston-rod assemblies from top of cylinder block, turning crankshaft as necessary to facilitate removal.
44. Remove main bearing caps together with bearing inserts.
45. Remove crankshaft and take out upper bearing inserts.
46. Remove thrust ring halves from rear main bearing saddle.