Disassembly Sequence

 
 

     (Updated:  7Feb07)  

 

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Here's a list of the steps required to remove and reinstall the engine in my car.  It's not complete by any means so use it at your own risk. Note that the sequence includes the removal of the Powerdyne supercharger.  I'm planning making refinements to the list when time permits.
 

  

 

 
 

 

 1 disconnect battery pos.5/16, and neg.3/8; and hold down 13mm
2. remove the battery and begin trickle charge
3. remove the alternator
4. remove valve covers
5. remove the throttle body cable cover
6 . remove the fuel tank filler cap
7. relieve fuel system pressure
8. disconnect fuel supply and return spring lock connectors; set aside
9. disconnect throttle and cruise control cable at throttle body
10. remove alternator power lead and connector 13mm
11. remove throttle cable; cruse control cable
12. remove brake booster vacuum hose
13. remove powerdyne intake elbow
14. remove airpump outlet hose
15. remove ignition coil leads and coil 14mm
16. remove ignition coil bracket
17. remove coil wire
18. remove upper radiator support 8mm
19. remove powedyne discharge tube
20. remove powerdyne drive belt 9/16
21. remove accessory drive belt
22. drain cooling system
23. remove the small dia.radiator to water pump hose lower left on radiator
24. disconnect right and left cooling fan connector
25. remove the cable clamps from the fan shroud
26. remove the cable tie from the right side of radiator. Don't cut.
27. release fan assembly by raising up and remove from bottom
28. remove radiator overflow tube from radiator
29. remove the connector from the radiator low coolant sensor
30. remove radiator bypass tube. (just below radiator cap)
31. remove main radiator inlet and outlet hoses
32. discharge a/c
33. remove lower a/c condenser hose 20mm, 24mm
34. remove upper a/c condenser hose 10mm
35. remove the upper bolt to powerdyne tensioner bracket 9/16
36. remove the powerdyne inlet tube
37. remove 6 bolt & 2 spacers securing powerdyne
38. remove powerdyne drive pulley 3 bolts 5/8
39. remove balancer
40. remove drivers side ignition wires
41. remove the plastic shroud for a/c on core support
42. remove the heater hose from the water pump, passenger side
43. remove the air pump hose from the passenger side rear header tube
44. remove throttle body, AIC connector, 4 bolts, 10mm
45. disconnect the passenger side upper water pump hose
46. remove 2 bolts securing power steering pump to bracket 10mm
47. remove front 3 bolts securing a/c/ compressor 13mm
48. remove 2 bolts securing the belt tensioner 10mm (bolt is an 8mm x 1.25 thread)
49. remove 4 bolts securing the accessory bracket 14mm upper = short;
next down = short
next down = long
bottom = medium
50. remove a/c compressor rear bracket to engine block bolt 14mm
51. pull the accessory bracket forward and remove the air tube routed behind
the power steering pump and under the harmonic balancer
52. disconnect the a/c compressor wire harness to clutch
53. disconnect a/c compressor wire harness clip from accessory bracket
54. remove the accessory bracket from behind p/s pump and a/c compressor. (lots of wiggling)
55. disconnect power steering pump outlet 16mm
56. disconnect p/s pump reservoir 10mm
57. disconnect hose from p/s reservoir
58. remove p/s pump and reservoir from car
59. route p/s pump hoses between a/c compressor body and the inlet and outlet tubes
60. remove the connector from water pump temp sensor and two water pump cable clamps.
61. disconnect connector from coolant temp sensor and clamp above #1 spark plug 13/16
62. disconnect the copper ground strap (to ignition coil) from the chassis on the drivers side 10mm
63. disconnect wire harness from accelerator cable bracket
64. disconnect fuel injector connectors
65. remove PCV valve and tube from car
66. disconnect oil pressure and EGR control connectors
67. disconnect canister purge and MAP sensor connectors
68. disconnect harness from clamps on right front of fuel rail
69. remove optispark harness at optispark to canister purge bracket
70. remove 4 nuts securing brackets to intake manifold studs 14mm
71. disconnect vacuum control tube to EGR and remove EGR control from car
72. remove 12 intake bolts
73. remove the intake manifold
74. remove 2 bolts securing rear of cat. converter 15mm
75. remove O2 sensors 22mm
76. remove Y-pipe 9/16 with 8mm cap screws
77. remove 4 spark plugs from drivers side
78. remove drivers side header pipe 3/8
79. remove the starter 2 bolts, 14mm
80. remove the starter power and control wires 13mm, 8mm
81. remove passenger side spark plugs 5/8
82. remove passenger header and dip stick tube together from the top 3/8
83. remove the clamp securing 2 wires to passenger motor mount 14mm
84. remove clutch slave, let hang 13mm
85. remove drive shaft 11mm
86. remove the shifter:
remove shift knob
remove shifter boot and leather
remove bolts in rear bottom console 10mm
remove console bezel, glove box light, ashtray light and cigarette lighter connector
remove the bolt in the center of console 10mm
remove the console shell
remove the screws securing the rubber shifter dust boot 7mm
remove four bolts securing the shifter 1/2"
remove the shifter
87. disconnect harness from oil level sender
88. disconnect harness from on drivers side transmission
89. pull drivers side harness up from the top of engine
90. remove drivers side O2 sender from harness
91. remove engine mount thru-bolts 18mm nut, 15mm bolt
92. remove the engine from the car (with the transmission attached)
Attach the hoist to the cylinder heads at the second pair of
intake manifold bolt holes from the front of the engine.
93. remove 8 bolts securing the transmission 15mm
94. remove bolts securing the bell housing dust cover 10mm
95. remove the 6 bolts securing the bell housing to block 15mm
96. remove the 6 bolts securing the clutch disk and pressure plate 9/16
97. remove 6 bolts securing flywheel 9/16
98. remove the bracket from left rear cylinder head 14mm
99. remove the steam relief line from rear of cylinder heads 15mm
100. remove the supercharger bracket and brace
101. remove the 6 bolts securing water pump and pump 14mm
102. remove the water pump drive coupling (stud is on the left middle mounting hole)
103. remove 3 bolts securing optispark and optispark 3/8
104. remove crank hub and pulley 5/8 (bolt gets spacer and washer)
105. remove right cylinder head, note the presence of the water jacket plug between the number 6
and 8 spark plug hole
106. remove left cylinder head
107. remove the oil level sender from oil pan
with the engine inverted, begin at the front left side (drivers) work clockwise
removing the 1/2 stud, 5-3/8 bolts, 1-3/8 bolt and clamp, 1-3/8 bolt, 2-1/2 nuts,
4-3/8 bolts, 1-3/8 stud, 2-3/8 bolts, 1-1/2 stud
remove the left and right oil pan reinforcements
108. remove the timing cover chain 8 bolts, 3/8"
109. remove the water drain from the passenger side of block
110. remove plug wire bracket from left side of block 3/8
111. remove plug wire bracket from right side of block 3/8, 1/2 (stud and nut goes aft)
112. remove lifter hold down clamp 3 nuts 1/2 (notch is aft)
113. remove lifter retainers and lifters
114. remove oil pressure sender; back top of block 19mm
115. remove cam sprocket and chain 3-1/2
116. remove water pump drive gear 2-torx
117. remove oil pump drive gear from lifter galley 1/2
118. remove cam from front of engine
119. remove windage tray 3 nuts 9/16, 1 oil pump bolt 5/8
120. remove oil pump
121. remove 8 pistons and rods 9/16
122. remove oil filter adapter from block 7/16
123. remove knock sensor from right side of block 22mm
124. remove rear main seal 3 bolts 3/8, 1 nut 7/16
         
         
    Reverse the process to assemble.