Engine Disassembly

1. Remove torque stopper housing, if equipped, then the engine mounts.
2. Remove alternator with mounting bracket, then the A/C compressor, power steering pump and cooling fan bracket, as required.
3. Remove lower inlet pipe assembly with water hose.
4. Remove engine oil dipstick, then the secondary air pipes, if equipped.
5. Remove ignition wires, spark plugs and distributor.
6. Remove thermostat and coolant outlet.
7. On 626 models, remove insulator assembly(s), then the front catalytic converter and exhaust pipe.
8. On all models, remove exhaust manifold, oxygen sensor and turbocharger, as required.
9. Remove coolant bypass hose, then the intake manifold assembly.
10. On carbureted models, remove fuel pump and gasket.
11. Remove oil filter, oil cooler, oil pressure switch and knock sensor, if equipped.
12. Install ring gear brake (49 E301 060) to flywheel, then remove crankshaft pulley.
13. Remove upper and lower timing belt covers.
14. Loosen timing belt tensioner lock bolt, then remove tensioner spring, tensioner and timing belt.
15. Remove idler pulley, if equipped, then the camshaft pulley, while preventing it from turning with a suitable tool, and baffle plate, if equipped.
16. Remove front housing assembly, then the water pump and timing belt pulley.
17. Remove valve cover, then the rear housing assembly and fuel pump, as required.

Fig. 1 Rocker shaft bolt loosening sequence:

18. Remove rocker shaft assembly. Loosen attaching bolts in several steps in sequence, Fig. 1.

Fig. 2 Cylinder head bolt loosening sequence:

19. Remove camshaft, then the cylinder head assembly. Loosen cylinder head attaching bolts in several steps in sequence, Fig. 2.
20. Remove valve retainers, then the upper valve seats and valve springs.
21. Remove valves, then the lower valve spring seats.
22. Remove valve guides and clips, then the cylinder head gasket.
23. On models equipped with manual transaxle, remove clutch cover assembly, clutch and flywheel.
24. On models equipped with automatic transaxle, remove backing plate, drive plate assembly and adapter. Use ring gear brake (49 E301 060) to remove clutch cover assembly and flywheel or drive plate.
25. On all models, remove end plate, then the No. 3 engine bracket from front of engine, if equipped.
26. Remove oil pan, oil strainer and oil pump.
27. Remove rear cover assembly.
28. Remove connecting rod bearing caps and bearings.

Fig. 3 Piston pin removal:

29. Push piston and connecting rod assemblies out of cylinder block. Remove piston pins from pistons, Fig. 3.
30. Remove piston rings using a suitable ring expander.
31. Remove main bearing caps, then the crankshaft and pilot bearing.
32. Remove pilot bearing from crankshaft using needle bearing puller (49 1285 071).
33. Remove upper and lower main bearings.