Disassembly

1. Disconnect battery ground cable, then remove left and right engine mounts.
2. Remove A/C compressor and power steering pump and cooling fan brackets, then the alternator and alternator bracket.
3. Remove thermostat cover and thermostat, then the exhaust manifold and gasket.
4. Remove coolant bypass pipe, then disconnect spark plug wires at plugs and remove spark plugs and distributor.
5. Remove intake manifold, carburetor or throttle body assembly and gasket.
6. On manual transmission models, remove fuel pump and gasket.
7. On all models, remove oil filter, oil pressure switch and coolant inlet pipe.
8. Place ring gear brake tool 49E301060 or equivalent against flywheel, then remove crankshaft pulley and baffle plate.
9. Remove upper and lower timing belt covers.
10. Loosen tensioner lock bolt and remove timing belt tensioner and spring, then the timing belt and idler pulley. Using chalk, mark timing belt for direction of rotation and be careful not to get oil or grease on belt.
11. Remove camshaft pulley, using screwdriver to keep camshaft from turning.
12. Remove front housing, then the water pump assembly.
13. Remove timing belt pulley.
14. Remove cylinder head cover and gasket.

Fig. 1 Rocker Shaft Bolt Loosening Sequence:

15. Remove rocker arm, hydraulic lash adjuster and rocker shaft assembly, loosening bolts in two or three steps in proper sequence, Fig. 1.
16. Remove seal cap.
17. Remove camshaft.

Fig. 2 Cylinder Head Bolt Loosening Sequence:

18. Remove cylinder head bolts, loosening in two or three steps in proper order, Fig. 2, then the cylinder head.
19. Remove valve spring retainers, then the upper spring seats.
20. Remove valve springs, then the lower spring seats.
21. Using tools 490636100A and 49G030222, or equivalents, remove valves.
22. Remove valve seals, valve guides and clips.
23. Remove cylinder head gasket.
24. On engines with manual transmission, remove clutch cover, clutch disc and flywheel.
25. On engines with automatic transmission, remove backing plate, drive plate and adapter. Use ring gear brake (49E301060) to remove clutch cover assembly and flywheel or drive plate.
26. On all engines, remove end plate, then the oil pan and strainer.
27. Remove baffle plate, then the rear cover and oil seal assembly with gasket.
28. Remove oil pump assembly.
29. Remove connecting rod caps, then the connecting rod bearings.

Fig. 3 Piston Pin Removal:

30. Remove connecting rods and pistons, then the piston rings. Remove piston pins from pistons, Fig. 3.
31. Remove main bearing caps, then the crankshaft.
32. On models with manual transmission, remove pilot bearing from crankshaft, using Puller tool No. 49-1285-071 or equivalent.
33. On all models, remove main bearings.