Engine Disassembly

1. Exc. on 12 valve engine, proceed as follows:
a. Disconnect battery ground cable, then remove left and right engine mounts.
b. Remove A/C compressor and power steering pump and cooling fan brackets, then the alternator and alternator bracket.
c. Remove thermostat cover and thermostat, then the exhaust manifold and gasket.
d. Remove coolant bypass pipe, then disconnect spark plug wires at plugs and remove spark plugs and distributor.
e. Remove intake manifold, carburetor assembly and gasket.
f. On manual transmission models, remove fuel pump and gasket.
g. On all models, remove oil filter, oil pressure switch and coolant inlet pipe.
2. On 12 valve engine, proceed as follows:
a. Disconnect battery ground cable, then remove engine oil dipstick.
b. Remove power steering pump bracket, then the exhaust manifold insulator.
c. Remove EGR pipe and, on turbo models, the turbocharger oil pipe.
d. Remove exhaust manifold assembly, then, on turbo models, the turbocharger bracket.
e. Remove coolant inlet pipe and bypass hose, then the engine hanger.
f. Remove alternator, strap and bracket, then the engine mount bracket.
g. Remove distributor with wires attached, then the spark plugs.
h. Remove thermostat and thermostat cover.
i. Remove intake manifold bracket, then the intake manifold assembly.
j. Remove oil filter and, on turbo models, the oil cooler.
k. Remove oil pressure switch and, on turbo models, the knock sensor.
3. On all engines, place ring gear brake tool 49E301060 or equivalent against flywheel, then remove crankshaft pulley and, exc. on 12 valve engine, the baffle plate.
4. Remove upper and lower timing belt covers.
5. On 12 valve engine, remove baffle plate.
6. On all engines, 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.
7. Remove camshaft pulley, using screwdriver to keep camshaft from turning.
8. Exc. on 12 valve engine, remove front housing, then the water pump assembly.
9. On all engines, remove timing belt pulley.
10. Remove cylinder head cover and gasket.
11. On 12 valve engine, remove front and rear housings.
12. On 12 valve engine, measure camshaft endplay and oil clearance of camshaft journals.

Fig. 1 Rocker shaft bolt loosening sequence:

13. On all engines, remove rocker arm, hydraulic lash adjuster and rocker shaft assembly, loosening bolts in two or three steps in proper sequence, Fig. 1.
14. Remove seal cap (exc. 12 valve) or camshaft cap (12 valve).
15. Remove camshaft.

Fig. 2 Cylinder head bolt loosening sequence:

16. Remove cylinder head bolts, loosening in two or three steps in proper order, Fig. 2, then the cylinder head and, on 12 valve engine, the gasket.
17. Remove valve spring retainers, then the upper spring seats.
18. Remove valve springs, then the lower spring seats.
19. Using tools 490636100A and 49G030222, or equivalents, remove valves.
20. Remove valve seals and, exc. on 12 valve engine, the valve guides and clips.
21. Exc. on 12 valve engine, remove cylinder head gasket.
22. On all engines with manual transmission, remove clutch cover, clutch disc and flywheel.
23. 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.
24. On all engines, remove end plate, then the oil pan and strainer. On 12 valve engine, insert suitable tool between oil pan and baffle plate to separate them, being careful not to bend oil pan.
25. Remove baffle plate, then the rear cover and oil seal assembly with gasket.
26. On 12 valve engine, remove water pump.
27. On all engines, remove oil pump assembly.
28. On 12 valve engine, clean bearing, connecting rod and crankpin, then measure connecting rod side clearance and crankpin oil clearance.
29. On all engines, 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. On 12 valve engine, clean bearings, main journals and caps and measure crankshaft endplay and oil clearance of main journals.
32. On all engines, remove main bearing caps, then the crankshaft.
33. On models with manual transmission, remove pilot bearing from crankshaft, using tool 491285071 or equivalent.
34. On all models, remove main bearings.