Engine Assembly
OIL SEAL1. Place the rotor on a rubber pad or cloth.
Fig. 28 Stopper hole of oil seal ring:
Fig. 29 Installing oil seal springs:
2. Install the oil seal springs in their respective grooves on the rotor with each round edge of the spring fitted in the stopper hole in the oil seal grooves as shown in Fig. 28. The oil seal springs have been painted in cream or blue color. The cream-painted springs should be fitted on the front faces of both front and rear rotors. While the blue-painted springs should be fitted on the rear faces, Fig. 29.
3. Install a new O-ring in each oil seal.
4. Place the inner oil seal in the oil seal groove so that the square edge of the spring fits in the stopper notch of the oil seal.
Fig. 30 Installing inner oil seal:
5. Press the inner oil seal by using a used inner oil seal so that the lip surface of the oil seal sinks into a position approximately 0.016 in. (0.4 mm) below the surface of the rotor, as shown in Fig. 30.
6. Place the outer oil seal to the oil seal groove so that the square edge of the spring fits in the stopper notch of the oil seal.
7. Push the oil seal slowly with fingers. When replacing the oil seal, confirm the smooth movement of the oil seal by placing the oil seal on the oil seal spring in the groove before inserting the O-ring. Be careful not to deform the lip of the oil seal.
8. Apply sufficient engine oil onto each oil seal, and confirm the smooth movement of each oil seal by pressing the oil seal.
9. Install the oil seal springs and oil seals on the other side of the rotor.
FRONT SIDE SEALS
1. Place front rotor on rubber pad or cloth with internal gear upward.
Fig. 31 Installing apex seal:
Fig. 32 Installing side seal:
2. Install apex seals without spring and side piece into their respective grooves so that side piece positions to the rear side of rotor, Figs. 31 and 32.
3. Apply engine oil onto each seal, and confirm the smooth movement of each seal by pressing its head.
FRONT HOUSING
1. Mount the front housing on engine stand.
2. Position thrust plate with chamfer facing toward front housing, then install needle bearing and plate, torquing to 12-17 ft.lbs.
3. Apply petroleum jelly to new outer and inner sealing rubbers.
4. Install outer sealing rubber so that white paint faces side wall in groove.
5. Install inner sealing rubber so that blue paint faces outer wall in groove and the seam is properly placed.
6. Ensure inner and outer sealing rubbers are not twisted.
7. Apply engine oil to contact surfaces, stationary gear and main bearing. Do not apply engine oil to sealing rubber.
FRONT ROTOR
1. Apply engine oil onto rotor oil seal, rotor bearing and the internal gear.
Fig. 33 Installing front rotor:
2. Place the front rotor assembly on the front housing taking care not to drop the seals into the port, Fig. 33.
Fig. 34 Meshing internal gear:
3. Mesh the internal gear and stationary gear so that one of the rotor apexes is set to any one of the four places shown in Fig. 34.
ECCENTRIC SHAFT
1. Lubricate the front rotor journal and main journal on the shaft with engine oil.
Fig. 35 Installing eccentric shaft:
2. Insert the eccentric shaft, being careful not to damage the rotor bearing and main bearing, Fig. 35.
FRONT ROTOR HOUSING
Fig. 36 Typical sealer application areas:
1. Apply sealing agent onto the front side of the front rotor housing, as shown in Fig. 36.
2. Apply petroleum jelly onto new O-ring and place the O-ring in front rotor housing.
Fig. 37 Positioning inner seal rubber:
a. On 1984-85 models, the wider line of the inner sealing rubber should face to combustion chamber and the seam of the sealing rubber should be placed at the position as shown in Fig. 37. Do not stretch the sealing rubbers.
Fig. 38 Installing sealing rubber protector:
b. On 1984-85 models, when engine overhauling, install the protector behind the inner sealing rubber, as shown in Fig. 38, to improve the durability of the sealing rubber.
3. Invert the front rotor housing and install it onto the front housing, being careful not to drop the sealing rubbers and O-ring.
Fig. 39 Installing tubular dowels:
4. Apply engine oil onto the tubular dowels and insert the tubular dowels through the front rotor housing holes into the front housing holes, as shown in Fig. 39.
Fig. 40 Installing apex seal spring. 1984-85:
REAR SIDE SEALS
1. Insert the each apex seal spring confirming the spring direction as shown in Fig. 40.
2. Install the corner seal springs and corner seals into their respective grooves.
Fig. 42 Installing side seal & springs:
3. Install the side seal springs and side seals into their respective grooves, as shown in Fig. 42.
4. Fit each side piece to its original position, and confirm that the spring is set correctly on the side piece.
5. Apply engine oil onto each seal, and confirm the smooth movement of each seal by pressing its head.
6. Apply the sealing agent on the rear side of the front rotor housing, as instructed under ``Front Rotor Housing.''
7. Place new O-ring, sealing rubbers and protector on the rear side of the front rotor housing, as instructed under ``Front Rotor Housing.''
8. Apply engine oil onto the sliding surface of the front rotor housing. Make sure that the front rotor housing is free of any foreign matter.
INTERMEDIATE HOUSING
1. Apply petroleum jelly to new outer and inner sealing rubber.
2. Install outer sealing rubber to the front side so that the white paint faces the side wall in the groove.
3. Install inner sealing rubber to front side so that blue paint faces outer wall in groove and that seam is properly positioned.
4. Ensure outer and inner sealing rubbers are not twisted.
5. Apply engine oil to contact surfaces of intermediate housing. Do not apply engine oil to sealing rubber.
6. Apply engine oil to rotor oil seal on rear side of front rotor.
7. Apply petroleum jelly to new O-ring and install O-ring on rotor housing.
Fig. 36 Typical sealer application areas:
8. Apply a coat of suitable sealant as shown, Fig. 36.
9. Turn eccentric shaft so that rear rotor journal faces the intake and exhaust side.
10. Pull the eccentric shaft about 1 in. (25 mm), but do not pull over 1.5 in. (35 mm).
11. Install the intermediate housing through the eccentric shaft on the front rotor housing.
Fig. 43 Installing rear rotor:
Fig. 44 Installing rear housing (Typical):
REAR ROTOR & REAR ROTOR HOUSING
1. Turn the engine on the engine stand so that the rear of the engine is up.
2. Install the rear rotor and rear rotor housing, Figs. 43 and 44. Side piece of rotor seals must be facing rear housing side.
3. Install tubular dowel pin.
REAR HOUSING
1. Apply engine oil to new rear oil seal and the groove of the rear stationary gear.
2. Install oil seal into rear stationary gear.
3. On 1986-88 models, install oil regulator valve, torquing to 65-80 ft.lbs.
4. On all models, Apply petroleum jelly to new outer and inner sealing rubbers.
5. Install outer sealing rubber so that white paint faces side wall in groove.
6. Install inner sealing rubber so that blue paint faces outer wall in groove and seam is properly positioned.
7. Ensure inner and outer sealing rubbers are not twisted.
8. Apply sufficient engine oil onto the contact surfaces, stationary gear and main bearing. Do not apply engine oil to sealing rubber.
9. Apply engine oil to rotor oil seal of rear rotor's rear side.
10. Apply petroleum jelly to new O-ring and install O-ring in rear housing.
Fig. 36 Typical sealer application areas:
11. Apply coat of suitable sealant as shown, Fig. 36.
12. Install the rear housing on the rear rotor housing. Ensure side pieces of front and rear apex seals are not wedged between rotor housing and side housing.
TORQUING TENSIONING BOLTS
1. Install a new sealing washer to each tension bolt.
2. Apply engine oil onto bolt threads.
Fig. 45 Tension bolt tightening sequence:
3. Install tension bolts and torque in sequence, Fig. 45, in several steps to 23-29 ft.lbs. on models with fuel injected engine or 23-27 ft.lbs. on all other models. Note that some engines will not have the No. 11 tension bolt. Also on 1986-88 models, the bolt marked ``m'' is for the No. 17 bolt position.
4. Turn the eccentric shaft and make sure that the rotation is light and smooth. Replace the sealing washer in the tension bolt when the engine is overhauled.
FLYWHEEL
Manual Transmission
1. Turn the engine so that the top of the engine is up.
2. Apply engine oil to the oil seal in the rear housing.
3. Fit the key into keyway on the eccentric shaft.
4. Install the flywheel to the rear end of the eccentric shaft, aligning the keyway of the flywheel with the key.
5. Apply sealing agent to both sides of the flywheel lock washer and place it in position. Install the nut.
6. Install the suitable flywheel brake and with the box wrench (49 0820 035) tighten the nut to 290-360 ft.lbs. (40.0-50.0 m-kg).
7. Bend the tab of the lockwasher.
8. On 1984-85 models, install the clutch disc and clutch cover assembly on the flywheel.
COUNTER WEIGHT
Automatic Transmission
1. Turn the engine so that the top of the engine is up.
2. Apply engine oil to the oil seal in the rear housing.
3. Fit the key into keyway on the eccentric shaft.
4. Install counter weight to the rear end of the eccentric shaft, aligning the keyway of the counter weight with the key.
5. Apply sealing agent to inner side of the locknut and place it in position.
6. Install the stopper (49 1881 055) and with the box wrench (49 0820 035) tighten the nut to 40.0-50.0 m-kg (289-362 ft.lbs.).
7. Bend the tab of the lockwasher.
Fig. 46 Installing drive plate:
8. Install the drive plate on the counter weight as shown in Fig. 46 and tighten the attaching bolts.
CHECKING ECCENTRIC SHAFT ENDPLAY
1. Turn the engine on the engine stand so that the front of the engine is up.
2. Fit the thrust plate with the chamfer downward, and slide the spacer and needle bearing onto the eccentric shaft, then apply sufficient engine oil onto them.
3. Place the bearing housing on the front housing. Tighten the attaching bolts with washers. If the bearing housing has not been removed from the front housing, special care should be taken when installing the spacer, so that the center of the needle bearing in the bearing housing comes to the center of eccentric shaft, and the spacer should be seated to the thrust plate.
4. Slide the needle bearing onto the shaft, and apply engine oil onto it.
5. Slide the balance weight together with the thrust washer onto the shaft.
6. Install oil pump assembly on front housing.
7. Fit the key into keyway on the oil pump shaft.
Fig. 1 Removing oil pump drive:
8. Fit the oil pump drive chain onto the oil pump sprocket and eccentric shaft sprocket, and install them to the eccentric shaft and oil pump shaft, aligning the key and keyway, Fig. 1.
9. Align the keyways of the eccentric shaft sprocket and balance weight, and install the key.
Fig. 47 Installing distributor drive gear:
10. Slide the distributor drive gear onto the eccentric shaft with ``F'' mark toward the front of engine, Fig. 47.
11. Install the eccentric shaft pulley onto the shaft aligning the keyway of the pulley with the key.
12. Install the pulley bolt and washer.
13. Turn the engine on the engine stand so that the top of the engine is up.
Fig. 48 Checking eccentric shaft endplay:
14. To check the eccentric shaft endplay, position a dial indicator on the rear housing so as to contact the feeler with the flywheel or the counter weight as shown in Fig. 48.
15. Move the flywheel fore and aft, and note the reading of the indicator. The standard endplay is 0.0016-0.0028 in. (0.04-0.07 mm).
Fig. 49 Eccentric shaft endplay:
16. If the endplay is more than 0.0035 in. (0.09 mm), adjust it by grinding the spacer, Fig. 49, on the surface plate using an emery paper or by replacing the spacer with a thinner one.
17. If the endplay is less than 0.0016 in. (0.04 mm), replace with a thicker spacer.
The spacers are available in the following thicknesses:
Ident.Mark Thickness
CS 0.3197 inch (8.12 mm)
CT 0.3189 inch (8.10 mm)
CX 0.3181 inch (8.08 mm)
CK 0.3173 inch (8.06 mm)
CY 0.3165 inch (8.04 mm)
CV 0.3158 inch (8.02 mm)
CZ 0.3150 inch (8.00 mm)
18. If the endplay is 0.0016-0.0035 in. (0.04-0.09 mm), proceed as follows to install the oil pump chain adjuster.
FRONT COVER
1. Turn engine on engine stand so that front of engine is up.
2. Remove eccentric shaft pulley.
3. Tighten oil pump sprocket nut and bend tab of lock washer.
4. Check oil pump drive chain slack. If slack exceeds 0.047 in. (12 mm), replace drive chain.
5. Place new O-ring on oil passage of front housing.
6. Place gasket and front cover on front housing and tighten attaching bolts.
7. Apply engine oil onto oil seal in front cover.
8. Install eccentric shaft pulley onto shaft and tighten pulley bolt. Use new washer in eccentric shaft pulley bolt when pulley is removed.
Fig. 51 Cutting off excess gasket:
3. Cut off the excess gaskets along the mounting surface of the oil pan, as shown in Fig. 51.
Fig. 52 Sealer application areas:
4. Apply the 0.16-0.24 in. (4-6 mm) diameter continuous bead of sealer (Part number 0398 77 739) on the mounting surface of the oil pan as shown in Fig. 52. Be sure there are no gaps in the sealer bead.
5. Position the oil pan on engine.
6. Install bolts and torque alternately and evenly to 6-8 ft.lbs.
MANIFOLD & CARBURETOR ASSEMBLY
Exc. Fuel Injected Engine
1. Place the O-rings and gasket in position.
2. Install intake manifold and carburetor assembly and tighten the attaching nuts.
3. Install the thermal reactor covers and tighten the attaching bolts and nuts.
4. Connect the air outlet hose valve to the air control valve.
5. Connect the oil hoses to metering oil pump outlets.
6. Connect the metering oil pump connecting rod to the metering oil pump lever with washer and cotter pin.
7. Connect the vacuum sensing tube to the vacuum control unit of the distributor.
FINAL ASSEMBLY
Install components removed as described under ``Preliminary Components'' in the reverse order of removal to complete engine assembly, noting the following:
PRELIMINARY COMPONENTS
Exc. Fuel Injected Engine
1. Remove deceleration control vale.
2. Remove vacuum control valve.
3. Remove EGR valve and solenoid.
4. Remove air pump.
5. Remove alternator.
6. Remove thermal reactor or exhaust manifold.
7. Remove distributor.
8. Remove engine mount.
9. Remove oil filter, cover and/or oil cooler.
Fuel Injected Engine
1. Remove engine mount.
2. Remove air pump.
3. Remove alternator.
4. Remove attaching bolts from emission control valve mounting bracket located on top of engine.
5. Remove delivery pipe attaching bolts.
6. Remove emission control valve mounting bracket and delivery pipe as an assembly.
7. Remove fuel injection nozzles.
8. Remove metering oil pump lines.
9. Remove intake manifold and gasket.
10. Remove auxiliary port valves.
11. Remove exhaust manifold covers, exhaust manifold and gasket.
12. Remove distributor.
13. Remove oil filter and body.
14. Remove eccentric shaft pulley.
Fig. 53 Water pump tightening sequence. 1984-85:
1. When installing water pump on 1984-85 models, torque nuts in sequence, Fig. 53, to 13-20 ft.lbs. Do not forget to use shims on side housing contact surfaces indicate by (2) and (4), Fig. 53.
2. On 1984-85 models, install oil filter and distributor as follows:
a. Attach two O-rings to oil filter body and install body.
b. Align yellow painted leading timing mark on eccentric shaft pulley with indicator pin on front cover.
c. Align tally marks on distributor housing and driven gear.
d. Install distributor and locknut and turn distributor housing until projection of signal rotor aligns with core of leading side pickup coil, then tighten locknut.
e. Install distributor rotor and cap.
Fig. 54 Installing auxiliary port valves:
3. When installing intake manifold auxiliary port valves on fuel injected models, install so that bigger side of pin is aligned to mating mark, Fig. 54.
4. When installing water pump on 1986-88 models, do not forget to use shims on studs where the gasket does not mount.
5. When installing housing and manifold oil nozzles on 1986-88 models, note that oil tube ends are color code: front rotor housing, white; rear rotor housing, yellow; front inlet port, blue; rear inlet port, green.
Fig. 55 Adjusting metering oil connecting rod:
6. When installing metering oil connecting rod on 1986-88 models, check clearance as shown, Fig. 55. If clearance is not .039 inch (1 mm), adjust with shims. On turbocharged models, be sure to connect oil tubes so that colors of tube ends match numbers as shown, Fig. 55: (1), blue; (2), white; (3), green; (4), yellow.
7. When installing crank angle sensor on 1986-88 models, proceed as follows:
a. Turn eccentric shaft until leading top mark (yellow) is aligned with indicator pin.
b. Apply engine oil to new O-ring and install O-ring on crank angle sensor.
c. Apply engine oil to drive gear.
d. Match mating mark and install crank angle sensor on front housing, torquing to 69-95 inch lbs.