Engine Disassembly
ENGINE DISASSEMBLY/ASSEMBLYDisassembly Note
1. Remove the drive belt.
2. Remove the four bolts and the A/C compressor mounting bracket.
3. Disconnect the engine control sensor wiring from the generator.
4. Remove the bolts and the generator.
5. Disconnect the engine control sensor wiring from the:
^ engine coolant temperature sensor
^ water temperature indicator sender unit
^ forward ignition coil
6. Disconnect the engine control sensor wiring from the crankshaft position sensor.
7. Disconnect the engine control sensor wiring from the EGR solenoid and the radio ignition interference capacitor and the vacuum line from the EGR solenoid.
8. Disconnect the engine control sensor wiring from the rear ignition coil.
9. Disconnect the 8 spark plug wires.
10. Remove the bolts and the generator mounting bracket.
11. Remove the bolts.
12. Remove the water pump pulley.
13. Remove the water pump.
14. Disconnect the crankcase ventilation tube.
15. Disconnect the engine control sensor wiring from the:
^ idle air control valve
^ EGR transducer
^ throttle body
16. Disconnect the vacuum line.
17. Remove the water hose connection.
18. Remove the timing belt cover.
19. Remove the bolt and the washer.
20. Using the Crankshaft Damper Remover, remove the crankshaft pulley.
21. Release the timing belt tension.
^ Loosen the bolt.
^ Release the tension on the belt.
^ Tighten the bolt to hold the timing belt tensioner.
22. Remove the timing belt.
23. Remove the timing belt sprockets.
24. Remove the crankshaft position sensor.
25. Remove the timing belt tensioner.
^ Remove the adjustment bolt.
^ Loosen the tensioner pivot bolt.
^ Remove the timing belt tensioner.
26. Remove the timing belt shield.
27. Remove the camshaft position sensor.
28. Remove the oil pump inlet tube gasket and the oil pump.
29. Remove the EGR valve to exhaust manifold tube.
(1). Remove the bolts.
(2). Disconnect the tube from the exhaust manifold.
30. Disconnect the vacuum lines.
31. Remove the upper intake manifold bolts.
32. Disconnect the PCV valve and the coolant tube.
33. Remove the upper intake manifold.
34. Remove the intake manifold upper gasket.
35. Disconnect the fuel injectors.
36. Remove the right and left ignition wire sets.
37. Disconnect the oil pressure sensor, the bulkhead connector and remove the engine control sensor wiring.
38. Remove the oil level indicator tube.
39. Remove the valve cover bolts.
40. Remove the valve cover.
41. Remove the valve cover gasket.
42. Remove the cylinder head bolts.
43. Remove the cylinder head assembly.
44. Remove the head gasket.
45. Remove the oil separator and the 0-ring.
46. Remove the oil bypass filter.
47. Remove the coolant fitting.
48. Remove the oil pan bolts.
49. Remove the oil pan.
50. Remove the oil pan gasket.
51. Clean the sealing surfaces.
52. Remove the oil pump screen cover and tube and the oil pump inlet tube gasket.
53. Remove the front crankshaft seal retainer.
54. Remove the front crankshaft seal and the gasket.
55. Remove the nuts.
Note
^ Mark each pair of connecting rods (rods and caps).
56. Remove the connecting rod caps and lower connecting rod bearings.
57. Remove the piston and connecting rod assemblies.
58. Remove the bolts.
59. Remove the main bearing caps and lower bearings.
60. Remove the crankshaft rear oil seal.
61. Remove the crankshaft.
62. Remove the upper crankshaft main bearings.
63. If necessary remove the five pipe and core plugs.