Engine Assembly
VALVE, VALVE SEAL & SPRING
1. Apply clean engine oil to the inner surfaces of the new valve seal, then install valve seal on to the valve guide.
2. Install lower spring seat, then the valve. Install valve spring and upper spring seat into the cylinder head assembly. Install spring with its narrow pitch end toward the cylinder head.
3. Compress valve spring, then install spring retainer.
4. On DOHC engine, apply engine oil to sliding surfaces of hydraulic lash adjusters, then install them in the position from which they were moved, ensuring they move freely.
CONNECTING ROD
1. Align identification mark to cap of large end of connecting rod and F mark on piston.
2. Apply a coat of engine oil to circumference of each piston pin and to the small end of each connecting rod.
3. Place clip in clip groove in one side of piston and assemble piston and connecting rod.
4. Using tool 490221061A or equivalent, insert piston pin from opposite side and tap in until it contacts clip, then install other clip into groove in piston.
Fig. 28 Positioning piston rings:
PISTON RINGS
1. Install the three-piece oil rings on to the pistons as follows:
a. Apply clean engine oil to the oil ring spacer and rails.
b. Install the oil ring spacer.
c. Install the upper rail and the lower rail. After installing the upper and lower rails, ensure they turn smoothly in both directions. Do not align the end gaps, stagger them.
2. Install the second and top ring as follows:
a. Apply a liberal coat of clean engine oil on to the piston rings.
b. Install the second ring to the piston first, then the top one. The second and top rings must be installed with the R marks on the rings facing upward.
c. Position the opening of each ring as shown in Fig. 28.
OIL JETS
When installing oil jets, torque to 104-156 inch lbs.
CRANKSHAFT
1. Inspect oil clearances on the crankshaft and main bearings.
2. Remove any foreign material and oil from the journal and bearing.
3. Install the main bearings and the crankshaft.
4. Position Plastigage on top of each journal (in the journal axial direction), away from the oil hole.
5. Set the main bearing caps according to the cap number and forward mark and tighten cap bolts. Torque bolts to 40-43 ft.lbs.
6. Remove main bearing cap and measure oil clearance. Oil clearance should be .0011-.0027 inch for 1986 models or .0009-.0017 inch for 1987-88 models. If oil clearance exceeds specifications, grind crankshaft and use undersize main bearings. Undersize main bearings are available in undersizes of .010 inch, .020 inch and .030 inch.
7. Apply clean engine oil to main bearing and bearing journals.
8. Install the thrust bearings to the cylinder block side.
9. Install the crankshaft, and main bearing caps according to the cap number and forward direction mark on cap.
10. Check crankshaft endplay. Endplay should be between .0031-.0111 inch. If endplay exceeds specified amount, adjust endplay by using thrust bearings. Standard thickness available is .0984-.1004 inch. Undersize widths available are .010 inch, .020 inch and .030 inch. Oil groove of the thrust bearing must face the crankshaft.
PISTON & CONNECTING RODS
1. Apply clean engine oil to the cylinder walls, piston and piston rings.
2. Insert each piston and connecting rod into the cylinder block. Install pistons with F mark on piston facing front of cylinder block.
CONNECTING ROD CAP
1. Inspect and adjust the connecting rod bearing and crankshaft pin journal oil clearance by using the same procedure used for the crankshaft and main bearing oil clearance.
2. Torque connecting rod cap bolts to 37-41 ft.lbs. on 1986-87 models 35-38 ft.lbs. on 1988 SOHC engines or 48-51 ft.lbs. on 1988 DOHC engines. Align match marks on cap and on connecting rod when installing connecting rod cap.
3. Standard oil clearance is .0011-.0027 inch.
4. Undersize connecting rod bearings available are .010 inch, .020 inch and .030 inch.
5. Check side clearance of the connecting rod. Clearance should be .012 inch on SOHC engine, or .0118 inch on DOHC engine.
6. Apply clean engine oil to the crankpin journal and connecting rod bearing.
7. Install the connecting rod cap to align the match mark. Torque bolts to 37-41 ft.lbs. on 1986-87 models, 35-38 ft.lbs. on 1988 SOHC engine or 48-51 ft.lbs. on 1988 DOHC engine.
REAR COVER & END PLATE
1. Apply clean engine oil to the rear cover, oil seal and oil seal lip.
2. Using a suitable press, install oil seal into the rear cover.
3. Install the rear cover along with a new gasket.
4. Torque rear cover attaching bolts to 69-95 inch lbs.
5. Cut away seal portion protruding from the rear cover assembly.
6. Install end plate assembly.
7. Torque end plate attaching bolts to 65-95 inch lbs.
OIL PUMP, STRAINER, BAFFLE PLATE & OIL PAN
1. Remove any dirt or grease from pump contact surfaces.
2. Apply clean engine oil to the oil pump seal lip.
3. Install a new gasket. When installing gasket, do not allow gasket sealer to block pump oil hole.
4. Install oil pump. Torque oil pump attaching bolts to 14-19 ft.lbs.
5. Install oil strainer and a new gasket. Torque oil strainer attaching bolts to 69-95 inch lbs.
Fig. 30 Oil pan sealant areas. DOHC engine:
Fig. 31 Installing oil pump body and rear cover gaskets. DOHC engine:
6. Clean cylinder block sealing surface, then apply suitable sealant as shown, Fig. 30.
7. Install gaskets onto oil pump body and rear cover with projections in notches as shown, Fig. 31.
8. Thoroughly clean oil pan contact surface, then apply suitable silicone sealant to oil pan continuously with bead of .0984-.1378 inch, rimming the surface inside the bolt holes. After sealant is applied, pan must be secured within 30 minutes.
Fig. 32 Installing oil pan. DOHC engine:
9. Install oil pan. Oil pan projection and recession from end of cylinder block must not be more than .06 inch, Fig. 32. Tighten attaching bolts gradually in three steps, torquing to 69-95 inch lbs.
FLYWHEEL, CLUTCH DISC & COVER
1. Using a suitable drift and hammer, tap flywheel pilot bearing into flywheel.
2. Apply sealer 853077743 or equivalent, on to flywheel bolts. If original flywheel bolts are used, clean threads to remove old sealant, apply new sealant and torque attaching bolts to 71-75 ft.lbs. If old sealant cannot be removed, install new bolts.
3. Install flywheel and torque attaching bolts to 71-75 ft.lbs.
4. Install clutch disc and clutch cover, using clutch disc centering tool 49SE01301 or equivalent.
5. Torque clutch cover attaching bolts to 13-20 ft.lbs.
Fig. 33 Cylinder head bolt tightening sequence. DOHC engine:
CYLINDER HEAD
1. Thoroughly clean from top of cylinder block with clean, lint free rag.
2. Place new cylinder head gasket in position.
3. Install cylinder head, tightening attaching bolts gradually in order, Fig. 33. Torque bolts to 56-60 ft.lbs.
Fig. 34 Installing engine bracket & mount arm. DOHC engine:
ENGINE BRACKET & MOUNT ARM
Install engine bracket and mount arm, torquing bolts as follows, Fig. 34: bolt No. 1, 35-48 ft.lbs.; bolt No. 2, 44-63 ft.lbs.; bolt No. 3, 69-86 ft.lbs.; bolt No. 4, 27-38 ft.lbs.
WATER PUMP
1. Remove any dirt or old gasket from water pump mounting surface.
2. Place a new water pump gasket into position.
3. Install water pump. Torque pump attaching bolts to 14-29 ft.lbs. for 1986 models or 14-19 ft.lbs. for 1987-88 models.
Fig. 21 Camshaft cap bolt tightening sequence. DOHC engine:
CAMSHAFTS, CAMSHAFT OIL SEALS & SEAL PLATE
1. Apply engine oil to journals and set camshafts in position.
2. Apply thin coat of engine oil to camshaft oil seal and cylinder head and install camshaft oil seals.
3. Apply thin coat of suitable sealant to front camshaft cap surface.
4. Install camshaft caps, tightening cap bolts gradually in order, Fig. 21. Torque bolts to 100-126 inch lbs. Install camshaft cap according to cap number and arrow mark.
5. Install seal plate, torquing attaching bolts to 69-95 ft.lbs.
CAMSHAFT PULLEYS & CYLINDER HEAD COVER
1. Install camshaft pulleys. Install exhaust side pulley with E mark straight up and intake side pulley with I mark straight up.
2. Counter hold camshafts with suitable wrench and torque pulley attaching bolts to 36-45 ft.lbs.
3. Apply coating of suitable sealant in cylinder head cover grooves where upper end of gasket contacts.
4. Install cylinder head cover with new seal washers, torquing attaching bolts to 26-35 inch lbs.
5. Install filler cap and ventilation hose.
TIMING BELT PULLEY, IDLER, TENSIONER, BELT & COVERS
1. Reverse direction of tool 49E301060.
2. Install timing belt pulley and key, then apply suitable sealant to timing belt pulley attaching bolt and torque bolt to 80-94 ft.lbs.
Fig. 39 Aligning timing belt pulley:
3. Release tool 49E301060, then turn crankshaft so that timing mark on oil pump body is aligned with groove, Fig. 39.
4. Install idler pulley, torquing attaching bolt to 27-38 ft.lbs.
5. Install timing belt tensioner and tensioner spring, temporarily securing tensioner so that spring is fully extended.
6. Align crankshaft and camshaft timing marks, Figs. 39 and 40.
7. Install timing belt, keeping right side of belt as tight as possible. Timing belt must be installed in direction of previous rotation. Ensure there is no oil, grease or dirt on timing belt.
8. Turn crankshaft clockwise two full rotations and ensure timing marks are correctly aligned.
9. Loosen tensioner lock bolt and apply tension to belt, then torque lock bolt to 27-38 ft.lbs.
10. Turn crankshaft clockwise two full rotations and ensure timing marks align.
11. Measure tension of timing belt midway between camshaft pulleys. Belt deflection should be .33-.45 inch with 22 lbs. of force.
12. Install timing belt covers with new gaskets, torquing attaching bolts to 69-95 inch lbs.
CRANKSHAFT PULLEY
1. Install crankshaft pulley and baffle plate.
2. Torque crankshaft pulley attaching bolts to 11-13 ft.lbs. on SOHC cam engine or to 109-152 inch lbs. on DOHC engine.
FUEL PUMP
Carbureted Models Only
1. Apply clean engine oil to the fuel cam contact surface.
2. Install fuel pump, insulator and gasket.
3. Torque fuel pump attaching bolts to 17-22 ft.lbs.
FINAL ASSEMBLY
1. Install water pump pulley, torquing attaching bolts to 69-95 inch lbs.
2. Install coolant inlet pie with new gasket, torquing attaching bolts to 14-19 ft.lbs.
3. Install thermostat with jiggle pin facing upward, then install thermostat cover with new gasket, torquing attaching bolts to 14-19 ft.lbs. Printed side of gasket must face thermostat.
4. Install alternator strap, torquing attaching bolt to 27-38 ft.lbs.
5. Install alternator and drive belt, then adjust belt tension, torquing alternator installation bolt to 27-38 ft.lbs. and the adjusting bolt to 14-19 ft.lbs.
6. Install oil pressure switch and knock sensor. Torque oil pressure switch to 104-156 inch lbs. and the knock sensor to 14-25 ft.lbs.
7. Apply engine oil to oil cooler O-ring and attach oil cooler to cylinder block, torquing attaching bolts to 22-29 ft.lbs. Oil cooler must be installed with triangle mark facing upward.
8. Install oil filter and hand tighten.
9. Install distributor as follows:
a. Apply engine oil to O-ring and position it on distributor.
b. Apply engine oil to drive gear, then install distributor with blade into camshaft groove.
c. Temporarily, loosely tighten distributor hold-down bolt.
10. Install spark plugs, torquing to 11-17 ft.lbs. and connect spark plug wires.
11. Install intake manifold assembly with new gasket, torquing attaching bolts to 14-19 ft.lbs.
12. Connect water hoses, air hose, ventilation hose and vacuum hose to intake manifold assembly. Hose clamps must be installed in original positions on hoses.
13. Install surge tank bracket, torquing upper and lower attaching bolts to 22-34 ft.lbs. and centermost attaching bolt to 14-19 ft.lbs.
14. Install front and rear engine hangers, torquing attaching bolts to 27-38 ft.lbs.
15. Install air intake pipe, torquing to 69-95 inch lbs. and connect air hose.
16. Apply a coat of coolant to coolant bypass hose O-ring and connect hose.
17. Install power steering pump and A/C compressor brackets, torquing power steering pump bracket attaching bolts to 35-48 ft.lbs. and the A/C compressor bracket attaching bolts to 27-38 ft.lbs.
18. Remove engine from workstand and install exhaust manifold gasket. Two piece type gasket must be installed onto cylinder head side.
19. Install exhaust manifold and turbocharger assembly, torquing attaching bolts to 29-42 ft.lbs.
Fig. 41 Installing turbocharger bracket:
20. Install turbocharger bracket, torquing attaching bolt A, Fig. 41, to 18-24 ft.lbs. and bolts B to 32-45 ft.lbs.
21. Connect oil return hose and the oil pipe, torquing oil pipe attaching bolt to 104-156 inch lbs. Ensure washers are installed on attaching bolt on both sides of oil pipe.
22. Connect water hose and install intake air hose bracket, torquing attaching bolt to 14-19 ft.lbs.
23. Install exhaust manifold insulator and wire clip, then the turbocharger insulator, torquing all attaching bolts to 14-19 ft.lbs.
24. Install air hose and the engine oil dipstick.