Disassemble

1. Draining Fluids and Oil Filter Removal
a. Remove the oil pan drain plug and allow the oil to drain.
b. Remove the oil filter.
c. Remove the knock sensor and the block coolant drain plug and allow the coolant to drain.





2. Engine Flywheel Removal
a. Remove the engine flywheel bolts.
b. Remove the engine flywheel.





3. Oil Level Indicator and Tube Removal
a. Remove oil level indicator from the tube.
b. Remove the oil level indicator tube bolt from the right cylinder head.
c. Remove the oil level indicator tube from the engine block.
4. Exhaust Manifold Removal (Right Side)





a. Remove the secondary air injection pipe and check valve from the exhaust manifold. Do not remove the check valve from the pipe unless necessary.





b. Remove the EGR inset pipe, gasket and bolts.





c. Remove the studs and the bolts from the right exhaust manifold.
d. Remove the exhaust manifold.
e. Remove the exhaust manifold gasket.
f. Discard the gasket.
5. Exhaust Manifold Removal (Left Side)





a. Remove the secondary air injection pipe and check valve from the left exhaust manifold. Do not remove the check valve fronts the pipe unless necessary.





b. Remove the studs and the bolts from the left exhaust manifold.
c. Remove the exhaust manifold.
d. Remove the exhaust manifold gasket.
e. Discard the gasket.
6. Water Pump Removal

NOTE: Keep the ignition wires connected to the distributor until you remove the water pump. Make sure the coolant is drained.

a. Remove the water pump bolts.





b. Remove the water pump and gaskets.





c. Remove the coupling and the O-ring seats.
d. Discard the gasket and the O-ring seals.
7. Distributor Removal
a. Disconnect the spark plug harness from the spark plugs.
b. Disconnect the ignition harness from the ignition coil. Do not remove the wires from the distributor unless it is necessary.

CAUTION: Do not allow foreign material to enter the open vacuum lines. Cap the ends if necessary.





c. Disconnect the vacuum harness.
d. Remove the distributor bolts.





e. Remove the distributor.
8. Crankshaft Balancer and Hub Removal
a. Remove the crankshaft balancer bolts.





b. Remove the crankshaft balancer.
c. Remove the crankshaft balancer hub bolt and washer.





d. Use the Crankshaft Hub Remover and Installer in order to remove the crankshaft balancer hub.
9. Intake Manifold Removal
a. Remove the accelerator cable bracket bolts and bracket.





b. Remove the throttle body bolts, gasket and throttle body.





c. Remove the crankcase vent hose.





d. Remove the EGR valve, gasket and nuts.
e. Discard the EGR valve gasket.





f. Disconnect the fuel pressure regulator vacuum hose.





g. Remove the fuel rail bolts and fuel rail with injectors.





h. Remove the intake manifold bolts and studs.
i. Remove the intake manifold assembly.
j. Remove and discard the gaskets.
10. Valve Rocker Arm Cover Removal





a. Remove the valve rocker arm cover bolts.
b. Remove the valve rocker arm cover.
c. Remove and discard the gasket.
11. Valve Rocker Arm, Push Rod, and Stud Removal





a. Remove the following components from the cylinder head:
^ The valve rocker arm nuts (1)
^ The valve rocker arm balls (2)
^ The valve rocker arms (3)





b. Remove the valve rocker arm studs.





c. Remove the valve pushrods.
d. Place the following parts in a rack so that they can be reinstalled in their original locations:
^ The valve rocker arms
^ The valve rocker arm balls
^ The valve pushrods
12. Valve Lifter Removal





a. Remove the valve sifter guide retainer and bolts.





b. Remove the valve sifter guides.
c. Place the components in a rack so that they can be reinstalled to their original location.

NOTE: Some valve lifters may be stuck in their bores because of gum or varnish deposits. Use the Valve Lifter Remover (Plier Type) or the Valve Lifter Remover (Slide Hammer Type) in order to remove these valve lifters.





d. Use the Valve Lifter Remover (Plier Type) in order to remove the valve lifters.





e. If the valve lifters cannot be removed with the Valve Lifter Remover (Plier Type) use the Valve Lifter Remover (Slide Hammer Type) in order to remove the valve lifters.
13. Cylinder Head Removal





a. Remove the engine coolant air bleed pipe bolts, pipe, and seating washers. Use a backup wrench on the pipe fitting when you remove the bolts.
b. Remove the ignition coil and the ignition coil bracket from the cylinder head.
c. Remove the cylinder head bolts.

CAUTION: After removal, place the cylinder head on two wood blocks to prevent damage.





d. Remove the cylinder head.
e. Remove and discard the gasket.
14. Oil Filter Adapter and Valve Assembly Removal
a. Remove the oil filter adapter bolts.





b. Remove the oil filter adapter, oil seat and gasket.
15. Oil Pan Removal

CAUTION: You must remove the oil level sensor in order to prevent it from getting damaged when you remove the oil pan.





a. Remove the oil level sensor.
b. Remove the following fasteners from the oil pan:
^ The bolts
^ The nuts
^ The studs





c. Remove the oil pan reinforcements.
d. Remove the oil pan.
e. Remove the oil pan gasket.





16. Oil Pump Removal
a. Remove the crankshaft oil deflector nuts (6) and deflector (2).
b. Remove the bolt (1) that attaches the oil pump to the rear crankshaft bearing cap.
c. Remove the oil pump (3), the driveshaft (5), and the retainer (4).
17. [1][2]Engine Front Cover Removal
a. Remove the crankshaft position sensor bolt.





b. Remove the crankshaft position sensor.





c. Remove the [1][2]engine front cover bolts.
d. Remove the [1][2]engine front cover.
e. Remove and discard the gasket.
f. Remove the oil seats from the front cover.
g. Clean the [1][2]engine front cover in solvent.
h. Inspect the following parts:
^ The front engine cover for damage to the gasket surface or crankshaft position sensor bore surface.
^ The crankshaft position sensor bolt hole threads for damage.
18. Timing Chain, Sprockets, and WP Driveshaft Removal.





a. Remove the crankshaft position sensor reluctor ring.





b. Remove the camshaft sprocket bolts.
c. Remove the camshaft sprocket.
d. Remove the timing chain.





e. Remove the crankshaft sprocket.
f. If necessary, remove the crankshaft sprocket key.





g. Use the Water Pump Driveshaft Remover in order to remove the water pump driveshaft.
19. Camshaft Removal.





a. Remove the oil pump driveshaft bolts.
b. Remove the oil pump driveshaft.
c. Remove the camshaft retainer bolts and retainer.

CAUTION: All camshaft journals are the same diameter, so care must be used in removing the camshaft to avoid damage to the bearings.





d. Remove the camshaft.
^ Install the three 5/16-18 x 4.0 inch bolts in the camshaft front bolt hoses.
^ Carefully rotate and putt the camshaft out of the bearings.
20. Piston, Connecting Rod, and Bearing Removal





a. Remove the ring ridge.
^ Turn the crankshaft until the piston is at the bettors of the stroke.
^ Place a cloth on top of the piston.
^ Use a ridge reamer to remove cylinder ring ridge.
^ Turn the crankshaft so the piston is at the top of the stroke.
^ Remove the cloth.
^ Remove the cutting debris.

NOTE: Place matchmarks or numbers on the connecting rods and the connecting rod caps. Assemble the connecting rod caps to the matching connecting rods.





b. Remove the connecting rod nuts.
c. Remove the connecting rod cap.
d. Remove the connecting rod bearings.
^ Keep the bearings with the original connecting rod and connecting rod cap.
^ Wipe the oil from the bearings.
^ Wipe the oil from the crankpins.





e. Use the Guide Set in order to remove the connecting rod and the piston out of the top of the engine block.
21. Crankshaft Rear Oil Seal and Housing Removal
a. Remove the crankshaft rear oil seal housing nuts and bolts.





b. Remove the crankshaft rear oil seal housing, seal, and gasket.





c. Remove the crankshaft rear oil seal from the crankshaft rear oil seal housing.
d. Discard the gasket and seal.





22. Crankshaft, Bearings, and Bearing Cap Removal
a. Remove the crankshaft bearing cap bolts and studs.
b. Remove the crankshaft bearing caps.
c. Remove the crankshaft.
d. Remove the crankshaft bearings from the bearing caps and from the engine block.
23. Camshaft Bearing Removal





a. Remove the camshaft rear bearing hole plug.





b. Use the Camshaft Bearing Remover in order to remove the inner camshaft bearings. Repeat the following procedure for each of the inner camshaft bearings:
^ With the nut and the thrust washer installed to the end of the putter screw threads, index the pilot in the camshaft front bearing and install the puller screw through the pilot and the bearing to be removed.
^ Install the bearing toot with the shoulder toward the bearing.
^ Using two wrenches, hold the puller screw while you turn the nut in order to draw the bearing out of the bore.
^ When the bearing has been putted from the bore, remove the bearing toot and the bearing from the puller screw.
^ Index the pilot in the rear camshaft bearing in order to remove the rear inner camshaft bearing.
c. Use the Camshaft Bearing Remover in order to remove the front and rear camshaft bearings.
^ Assemble the bearing tool to the driver.
^ Drive the front and rear bearings out of the block bore. Drive inward toward the center of the engine block.