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. 41 Installing apex seal spring. 1986-88:
REAR SIDE SEALS
1. Insert the each apex seal spring confirming the spring direction as shown in Fig. 41.
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. Install spacer, thrust needle bearing, thrust washer, balance weight, oil pump drive sprocket and distributor drive gear on eccentric shaft. When installing needle bearing, ensure it is not wedged by spacer.
2. Install eccentric shaft pulley boss and torque pulley lock bolt to 80-98 ft.lbs.
3. Remove ring gear stopper or counter weight stopper.
Fig. 48 Checking eccentric shaft endplay:
4. Measure endplay of eccentric shaft, Fig. 48.
5. Attach ring gear brake 49F011101 or equivalent to flywheel, or counter weight stopper 491881055 or equivalent to counter weight.
6. Remove eccentric shaft lock bolt, distributor drive gear and oil pump sprocket.
7. If endplay is less than 0.0016 inch (0.04 mm), replace spacer with thicker one. If endplay is greater than 0.0035 inch (0.09 mm), replace spacer with thinner one. Spacers are available in thicknesses as described for 1984-85 models.
8. Apply engine oil to oil pump shaft, then install oil pump in front housing, torquing attaching bolts to 61-87 inch lbs.
9. Install key to oil pump shaft, then install oil pump drive gear, driven gear and chain as an assembly.
10. Install key to eccentric shaft, then install new washer and oil pump nut, torquing nut to 23-34 ft.lbs. Bend washer to locknut.
11. Install distributor drive gear so that chamfer surface faces housing.
FRONT COVER
1. Apply engine oil to new front oil seal and the groove of the front cover, then install oil seal in front cover.
2. Install oil pressure control valve in front cover, torquing to 29-36 ft.lbs.
3. Apply petroleum jelly to new O-ring and install O-ring on front cover with new gasket.
4. Apply engine oil to front oil seal lip, then install front cover with new gasket, torquing to 12-17 ft.lbs.
5. Install eccentric shaft pulley boss.
6. On 1987-88 models, proceed as follows:
a. Temporarily install lock bolt, tightening by hand.
b. Remove lock bolt and measure pulley boss protrusion, Fig. 50. If protrusion exceeds 0.0961 inch (2.44 mm), needle bearing may be wedged by spacer. Remove and reassemble needle bearing correctly.
c. Install bypass valve and spring into eccentric shaft.
7. On all models, apply engine oil to new O-ring and install O-ring on lock bolt.
8. Apply suitable locking compound to bolt threads.
9. Apply coat of suitable sealant to flange face of lock bolt and install bolt, torquing to 80-98 ft.lbs.
OIL STRAINER & OIL PAN
1. Turn the engine on the engine stand so that the bottom of the engine is up.
2. Place the oil strainer gasket and strainer on the front housing and tighten the attaching bolts.
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.
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
Fuel Injected Engine
1. Remove A/C compressor and power steering pump bracket.
2. Remove left engine mount.
3. Remove spark plugs and oil level gauge.
4. Remove oil filter and filter body.
5. Remove oil pressure gauge.
6. Remove crank angle sensor.
7. Remove air pump drive belt, air pump and air pump bracket.
8. Remove alternator drive belt and alternator.
9. Remove clutch cover and clutch disc.
10. Remove metering oil connecting rod, throttle and dynamic chamber.
11. On non-turbocharged models, proceed as follows:
a. Remove exhaust absorber plate, exhaust manifold and insulator.
b. Remove fuel injector and delivery pipe.
c. Remove air hose, manifold oil nozzle and metering oil tube.
d. Remove intake manifold, housing oil nozzle and metering oil tube.
e. Remove metering oil pump and eccentric shaft pulley.
f. Remove water pump, engine harness and vacuum lines.
g. Remove EGR valve.
12. On turbocharged models, proceed as follows:
a. Remove secondary vacuum piping.
b. Remove primary fuel injector and distribution pipe.
c. Remove air control valve, then the switching actuator.
d. Remove water pipe, then the turbocharger and insulator.
e. Remove air hose, housing oil nozzle and manifold oil nozzle.
f. Remove intake manifold, exhaust manifold and insulator.
g. Remove metering oil pump and eccentric shaft pulley.
h. Remove water pump, then the dynamic chamber bracket.
i. Remove engine harness, vacuum piping and oil inlet pipe.
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 0.039 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.