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Step	Instruction	Wrench Size	Torque
1	remove the hood.	1/2 in 4 places
2	disconnect battery neg. first; then pos.; then hold-down clamp	3/8; 5/16; 13mm
3	remove the battery and begin trickle charge
4	begin discharging the a/c system.
5	loosen the fuel tank filler cap to relieve pressure

	raise the vehicle
	Working inside the car:
103	remove shift knob
104	remove shifter boot and leather
	open the console door and remove console bezel, glove box light, ashtray light and cigarette lighter connector
105	remove bolts in rear bottom console	10mm
106	remove the bolt in the center of console	10mm
107
108	remove the console shell
109	remove the screws securing the rubber shifter dust boot (seven of them)	7mm
110	remove four bolts securing the shifter	1/2"
111	remove the shifter:



	Working under the car:
	drain the motor oil
	drain the transmission fluid	3/8 square-drive
	drain the coolant (anti-freeze)


6	remove 2 bolts securing rear of cat. converter	15mm
7	remove Y-pipe	9/16 with 8mm cap screws
	remove both O2 sensors	22mm
8
9	drop the starter, 2 bolts	14mm
10	remove the starter power and control wires	13mm, 8mm
11	remove 4 bolts securing the bell housing dust cover	10mm
12	disconnect wire from knock sensor
	remove knock sensor from right side of block	22 mm
13	remove ground from engine block at the right motor mount.	11mm
14	remove the clamp securing 2 wires to passenger motor mount	14mm
15	remove dip stick tube clamp bolt	3/8
16	remove the bracket securing the a/c compressor rear to engine block. lower bolt is short.	10mm
17	remove a/c compressor rear bracket to engine block bolt	14mm
18	remove drive shaft	11mm
19	remove the torque arm and transmission tail shaft mounting bracket	21mm / 15mm
20	disconnect harness from oil level sender
	remove oil level sender from the oil pan
21	disconnect harness from on drivers side transmission
22	pull drivers side harness up from the top of engine
23	remove drivers side O2 sender from harness
	remove balancer
24	remove tension from the accessory drive belt and remove the belt	1/2 socket
25	remove crank pulley	5/8
26	remove 2 bolts securing the belt tensioner	10mm (bolt is an 8mm x 1.25 thread)
27	disconnect right and left cooling fan connector
28	remove the cable clamps from the fan shroud
29	remove the cable tie from the right side of radiator. Don't cut.
30	remove the cable tie from the right side of radiator. Don't cut.
31	release fan assembly by raising up and remove from bottom
32	remove lower a/c condenser hose	20mm, 24mm
	remove clutch slave, let hang

	remove the oil filler from the right valve cover
	remove the air reactor to header fittings

33	remove the alternator	1/2" and 15mm
34	remove alternator power lead and connector	13mm
35	remove alternator bracket to intake bracket nut	9/16"
36	remove valve covers	3/8"
37	remove the throttle body cable cover	7mm
38	remove brake booster vacuum hose
39	relieve fuel system pressure
40	disconnect fuel supply and return spring lock connectors; set aside
41	disconnect throttle and cruise control cable at throttle body
42	remove throttle cable; cruse control cable

44	remove air pump outlet hose
45	remove coil wire
46	remove ignition coil leads and coil	14mm
47	remove ignition coil bracket
48	remove upper radiator support	8mm

		9/16
51

53	remove the small dia. radiator to water pump hose lower left on radiator
54	remove radiator overflow tube from radiator
55	remove the connector from the radiator low coolant sensor
56	remove radiator bypass tube. (just below radiator cap)
57	remove main radiator inlet and outlet hoses

59
60	remove upper a/c condenser hose	10mm





66	remove drivers side ignition wires
	remove the radiator and A/C condensor together
67	remove the plastic shroud for a/c on core support
68	remove the heater hose from the water pump, passenger side
69	remove the air pump hose from the passenger side rear header tube
70	remove throttle body, AIC connector,	4 bolts, 10mm
71	disconnect the passenger side upper water pump hose
72	remove 2 bolts securing power steering pump to bracket. Work through	10mm
	holes in the pulley.
73	remove front 3 bolts securing a/c compressor. 2, 6 and 11 o’clock.	13mm

77	disconnect the a/c compressor wire harness to clutch
78	disconnect a/c compressor wire harness clip from accessory bracket
79	disconnect the power steering pump discharge tube from the pump.	5/8

82	route p/s pump hoses between a/c compressor body and the inlet and outlet tubes
83	remove the connector from water pump temp sensor and two water pump cable clamps
84	disconnect connector from coolant temp sensor and clamp above #1 spark plug	13/16
85	disconnect the copper ground strap (to ignition coil) from the chassis on the drivers side	10mm
86	disconnect wire harness from accelerator cable bracket
87	disconnect fuel injector connectors
88	remove the EGR tube	1/2
89	remove PCV valve and tube from car
90	disconnect oil pressure and EGR control connectors
91	disconnect canister purge and MAP sensor connectors
92	disconnect harness from clamps on right front of fuel rail
93	remove Optispark harness at Optispark to canister purge bracket
94	remove 4 nuts securing brackets to intake manifold studs	14mm
95	disconnect vacuum control tube to EGR and remove EGR control from car	1/2
96	remove 12 intake bolts	9/16
97	remove the intake manifold
74	remove 4 bolts securing the accessory bracket
	upper = short;	13mm
	next down = short
	next down = long
	bottom = medium
81	remove the accessory bracket from behind p/s pump and a/c compressor. (lots of wiggling)

98	remove 4 spark plugs from drivers side
99	remove drivers side header pipe	3/8
100	remove passenger side spark plugs	5/8
101	remove passenger header and dip stick tube together from the top	3/8

113	remove coil bracket and stud from left front cylinder head.	9/16
114	remove the 6 bolts securing water pump and remove the pump	9/16
	(stud is on the left middle mounting hole)
115	remove the water pump drive coupling; groove goes toward motor.
	remove the Optispark distributer	3/8
116	Attach the hoist to the cylinder heads at the second pair
	of intake manifold bolt holes from the front of the engine.

118	remove the transmission mount to crossmember bolt	5/8
119	remove 4 transmission crossmember to frame bolts	15mm
120	remove motor mount to block bolts; 3 per side	9/16
121	remove motor mount to frame bolts; 3 per side	1/2
122	remove the engine from the car (with the transmission attached)

123	remove 8 bolts securing the transmission to bell housing	15mm
124	remove the 6 bolts securing the bell housing to block	15mm
125	remove the 6 bolts securing the clutch disk and pressure plate	9/16
126	remove 6 bolts securing flywheel to crank	9/16
127	place the motor on the engine stand






134	remove crank hub; (bolt gets spacer and washer)
135	remove the timing chain cover	8 bolts, 3/8
137	remove the left and right oil pan reinforcements
138	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
139	remove the oil pan
147	remove rear main seal	3 bolts 3/8, 1 nut 7/16
148	remove cam sprocket and chain	3 bolts 1/2
151	remove the oil pump driveshaft
152	remove windage tray	3 nuts 9/16, 1 oil pump bolt 5/8
153	remove oil pump	66 ft-lb.
155	remove main bearing caps	5/8 77ft.lbs. (ARP = 70 ft-lb.)
156	remove the crankshaft
157	remove the crankshaft bearings



	Reverse the process to assemble.

	Disassembly Sequence

	(Updated: 23 Mar 2008)
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