Federal Models

1. Disconnect battery ground cable and drain cooling system.
2. Remove air cleaner and air intake duct.
3. Remove cooling fan assembly.
4. Remove drive belts.
5. Remove water pump pulley.
6. Remove power steering pump mounting bracket bolts. Leave hoses connected and position pump assembly aside.
7. Remove A/C compressor support bracket. Leave compressor in place.
8. Disconnect coolant bypass hose and heater hoses at water pump and upper radiator hose at thermostat housing.
9. Disconnect ignition coil secondary wire from distributor cap, then remove distributor cap with ignition wires attached.
10. With No. 1 cylinder at TDC compression stroke, mark position of rotor to distributor housing and position of distributor housing to front cover.
11. Remove distributor hold-down clamp, then lift distributor from front cover.
12. Raise and support vehicle.
13. Remove crankshaft pulley using crankshaft damper remover T85P-6316-D and vibration damper removal adapter T82L-6316-B, or equivalents.

NOTE: If the vibration damper and the pulley are separated, mark them so that they may be reassembled in the same position. They are balanced as a unit.

14. Remove oil filter, then disconnect lower radiator hose from water pump.
15. Remove oil pan.

Front Cover & Water Pump Bolt Locations:

16. Lower vehicle and remove front cover attaching bolts. A front cover attaching bolt is located behind oil filter adapter. Tag bolts as they are removed so that they can be installed at same location.
17. Remove front cover and water pump as an assembly.
18. Remove camshaft bolt and washer from end of camshaft.
19. Remove distributor drive gear, then remove camshaft sprocket, crankshaft sprocket and timing chain.
20. If crankshaft sprocket is difficult to remove, pry off shaft using two large screwdrivers positioned on both sides of sprocket.
21. Remove chain tensioner assembly from front of cylinder block as follows:
a. Pull back on ratcheting mechanism.
b. Install pin through hole in bracket to relieve tension.
c. Remove three mounting bolts
22. Reverse procedure to install, noting the following:
a. If a replacement front cover is to be installed, the water pump, oil pump, oil filter adapter and intermediate shaft must be removed from the front cover to be replaced and reinstalled on the replacement front cover. When installing distributor, No. 1 cylinder must be at TDC position and marks made during removal must be aligned.
b. Lightly oil all bolt and stud threads before installation, except those specifying special sealant.
c. Rotate crankshaft as necessary to position piston No. 1 at TDC and crankshaft keyway at 12 o'clock position.
d. Lubricate timing chain and front oil seal with new clean engine oil.
e. Ensure timing marks are aligned across from each other.
f. Install distributor with rotor pointing at No. 1 cap tower.