Engine Assembly
PISTON & CONNECTING RODFig. 14 Piston & connection rod assembly:
Exc. 12 Valve Engine
1. Align oil hole in large end of connecting rod opposite the F mark on piston, Fig. 14.
2. Press piston pin into piston using tools 49G030042, 49G030043 and 49G030041 or equivalents. Insert the piston pin from the direction of the F mark on the piston. The piston pin should be pressed in, until lower portion of guide (tool 49G030043) meets bottom of block (tool 49G030041). Do not exceed 3300 lbs. when pressing pin into piston. If a force greater than 3300 lbs. is required, replace piston pin or connecting rod. After pressing pin into piston, hold piston head and raise crankshaft end of connecting rod until rod contacts piston. With connecting rod contacting piston, release crankshaft end of connecting rod. If connecting rod does not drop by its own weight, replace piston and connecting rod assembly. Repeat this procedure for all piston and connecting rod assemblies.
Fig. 15 Oil ring installation:
3. Install oil ring spacer, then the upper and lower side rails onto piston, Fig. 15.
Fig. 16 Compression ring installation:
4. Install compression rings (lower ring first), ensuring R marks face upward. Position rings as shown in Fig. 16.
5. Apply clean engine oil to piston, rings and cylinder walls, then install piston and connecting rod assemblies into cylinder block. The F mark on piston must face front of engine.
12 Valve Engine
1. Assemble tools 49G030043 and 49G030042, or equivalent, to piston pin and apply engine oil to pin.
2. Place piston on tool 49G030041 or equivalent with F mark facing upward.
3. Set connecting rod in piston with oil hole in large end opposite F mark.
4. Press piston into piston pin and connecting rod until tool 49G030043 contacts tool 49G030041. If pressing force is less than 1100 lbs. or more than 3300 lbs, replace piston pin or connecting rod.
5. After pressing pin into piston, hold piston head and raise crankshaft end of connecting rod until rod contacts piston. With connecting rod contacting piston, release crankshaft end of connecting rod. If connecting rod does not drop by its own weight, replace piston and connecting rod assembly. Repeat this procedure for all piston and connecting rod assemblies.
6. Install three piece oil rings as follows:
a. Apply engine oil to oil ring spacer and rails.
b. Install oil ring spacer so that opening faces upward.
c. Install upper and lower rails. Upper and lower rails are identical. Each rail can be installed with either face upward.
Fig. 15 Oil ring installation:
7. Check that both rails are expanded by the spacer tangs as shown, Fig. 15, by checking that both rails turn smoothly in both directions.
Fig. 16 Compression ring installation:
8. Using piston ring expander, install second ring to piston first, then install top ring, Fig. 16. Rings must be installed with R mark facing upward.
9. Apply liberal amount of clean engine oil to second and top piston rings.
10. Position opening of each ring as shown, Figs. 15 and 16.
CRANKSHAFT
1. Install main bearings into cylinder block and bearing caps. The shape of center main bearing on cylinder block side is different from that of the other main bearings.
2. Measure oil clearance between crankshaft journal and main bearing using Plastigage as follows:
a. Clean bearing and crankshaft journal.
b. Position Plastigage on top of journal in axial direction of journal.
c. Install main bearing cap and torque bolts to specifications.
d. Remove cap and measure oil clearance.
e. Clearance should measure 0.0012-0.0019 inch (0.031-0.049 mm) for all bearings on 1984-87 models and the No. 3 bearing on 1988 models, or 0.0010-0.0017 inch (0.025-0.043 mm) for Nos. 1, 2, 4 and 5 bearings on 1988 models. Clearance must not exceed 0.0031 inch (0.08 mm).
f. If clearance is not within specifications, grind crankshaft and install suitable undersize bearings. Bearings are available in undersizes of 0.010 inch (0.25 mm), 0.020 inch (0.50 mm) and 0.030 inch (0.75 mm).
3. Apply clean engine oil to bearings and journals, then install crankshaft and main bearing caps. Torque cap bolts to specifications.
4. Measure crankshaft endplay. Endplay should be .0012-0051 inch (0.03-0.13 mm) for 1984-85 626 and 1986 B2000 or .0031-.0071 inch (0.08-0.18 mm) on 1986-88 626, 1987-88 B2200 and 1988 MX-6 and must not exceed 0.012 inch (0.30 mm) on all models. If endplay is greater than specifications, install correct undersize bearing needed to bring endplay within allowable limits. Thrust bearings are available in undersizes of 0.010 inch (0.25 mm), 0.020 inch (0.50 mm) and 0.030 inch (0.75 mm).
5. On models equipped with manual transaxle, install pilot bearing as follows:
a. Apply clean engine oil to crankshaft and outer surface of bearing.
b. Position a pipe with an outside diameter of 1.18-1.34 inch against outer bearing race and drive bearing into place.
c. Apply suitable grease to bearing.
6. On all models, measure clearance between connecting rod bearing and crankshaft pin journal using Plastigage as described in step 2. Clearance should measure 0.0010-0.0026 inch (0.027-0.067 mm) and must not exceed 0.0039 inch (0.10 mm). If clearance is not within specifications, install undersize bearings as needed. Bearings are available in undersizes of 0.010 inch (0.25 mm), .020 inch (0.50 mm) and 0.030 inch (0.75 mm).
7. Install connecting rod bearing caps and torque attaching bolts to specifications.
Fig. 17 Connecting rod endplay check:
8. Measure connecting rod endplay, Fig. 17. Endplay must not exceed 0.012 inch (0.30 mm).
REAR COVER & END PLATE
1. Apply clean engine oil to rear cover and oil seal, then press seal into cover.
2. Install tubular pin, if used, into cylinder block.
3. Apply clean engine oil to seal lip, then install rear cover to cylinder block. Torque cover attaching bolts to 6-9 ft.lbs. (8-12 N-m).
4. Trim gasket protruding between oil pan and rear cover, then install end plate and torque attaching bolts to 14-22 ft.lbs. (19-31 N-m).
OIL PUMP, OIL STRAINER & OIL PAN
1. Apply suitable lithium based grease to O-ring, then install O-ring into oil pump body.
2. Apply suitable sealant to oil pump mating surface, then slide tubular pin, if used, into pump and install pump. Torque attaching bolts to 14-19 ft.lbs. (19-26 N-m) for 8 mm bolts or 27-38 ft.lbs. for 10 mm bolts.
3. Install baffle plate, if equipped, then the oil strainer. Torque attaching bolts to 6-9 ft.lbs. (8-12 N-m).
4. Apply a bead of suitable sealant to oil pan mating surface, then install oil pan. Torque attaching bolts to 5-9 ft.lbs. (7-12 N-m).
FLYWHEEL, CLUTCH & WATER PUMP
1. Install flywheel or drive plate assembly and torque attaching bolts to specifications. Lock assembly with ring gear brake (49 E301 060) when tightening bolts.
2. Install clutch disc and cover. Torque attaching bolts to 16-24 ft.lbs. (22-33 N-m).
3. On 626 models, install No. 3 engine bracket and torque attaching bolts to 27-38 ft.lbs. (38-53 N-m).
4. On all models, install water pump with a new gasket and torque attaching bolts to 14-19 ft.lbs. (19-26 N-m).
Fig. 18 Cylinder head bolt tightening sequence:
CYLINDER HEAD & ROCKER SHAFT ASSEMBLY
1. Install cylinder head assembly with new gasket. Torque attaching bolts to specifications in sequence, Fig. 18.
2. Install camshaft and check oil clearance as follows:
a. Clean bearing and camshaft journal.
b. Position Plastigage on top of journal in axial direction of journal.
c. Install bearing cap and torque to specifications.
d. Remove cap and measure oil clearance.
e. Exc. on 12 valve engine, clearance should measure 0.0014-0.0033 inch (0.035-0.085 mm) at No. 1 and 5 bearings, or 0.0026-0.0045 inch (0.065-0.115 mm) at No. 2 and 4 bearings, and must not exceed 0.0059 inch (0.15 mm) at any bearing. On 12 valve engine, clearance should be 0.0014-0.0033 inch (0.035-0.085 mm) at front and rear journals and 0.0026-0.0045 inch (0.065-0.115 mm) at center three journals and must not exceed 0.0059 inch (0.15 mm).
f. If clearances are not within specifications, replace cylinder head and camshaft cap.
3. Apply clean engine oil to camshaft and bearings, then install camshaft. Ensure camshaft knock pin is at 12 o'clock position.
4. On 12 valve engine, install hydraulic lash adjuster as follows:
a. Pour engine oil into oil reservoir in rocker arm.
b. Apply engine oil to new hydraulic lash adjuster.
c. Install hydraulic lash adjuster into rocker arm, being careful not to damage O-ring.
d. On 1984-86 models, apply clean engine oil to rocker shaft components and assemble rocker shaft assembly. Rocker arm shafts are not interchangeable. Rocker arms Nos. 1 and 3 are identical and Nos. 2 and 4 are also identical.
Fig. 19 Rocker arm & shaft assemblies. 1987-88 exc. 12 valve engine:
Fig. 20 Rocker arm & shaft assemblies. 12 valve engine:
5. On 1987-88 models, assemble rocker arms, hydraulic lash adjusters, rocker shafts and camshaft bearing caps as shown, Figs. 19 and 20. Ensure rocker arm shaft oil holes in center camshaft cap face each other. Use installation bolts for alignment.
Fig. 21 Rocker shaft bolt tightening sequence:
6. Apply suitable sealant to front and rear rocker shaft-to-cylinder head mating surfaces, then install rocker shaft assembly. Torque attaching bolts to specification, following the torquing sequence in Fig. 21.
Torque Specification: 13 - 20 ft-lb (18 - 26 N-m, 1.8 - 2.7 m-kg)
FRONT HOUSING & TIMING BELT
Exc. 12 Valve Engine
1. Apply clean engine oil to front housing and oil seal mating surfaces, then press seal into housing.
2. Install front housing assembly with a new gasket. Torque attaching bolts to 14-19 ft.lbs. (19-26 N-m).
3. Install timing belt pulley with semicircular key. Torque pulley retaining bolt to 80-87 ft.lbs. (110-120 N-m) for 1984 models, 108-112 ft.lbs. (150-160 N-m) for 1985 models, 117-125 ft.lbs. (160-170 N-m) for 1986 626, 108-116 ft.lbs. (147-157 N-m) for 1986 B2000 or 116-123 ft.lbs. (157-167 N-m) for 1987 626 and 1987-88 B2200, after reversing direction of ring gear brake. Ensure reference mark on oil pump body aligns with semicircular key.
4. Install camshaft pulley and torque retaining bolt to 35-48 ft.lbs. (48-66 N-m). Camshaft pulley must be installed so that (A) or (triangle) mark on pulley is at 12 o'clock position and aligns with mark on front housing.
5. Install timing belt tensioner, tensioner spring and idler, if equipped. Slide tensioner as far as possible toward intake side, then tighten lock bolt to temporarily hold in place.
6. Install timing belt. Adjust belt tension as follows:
a. Loosen tensioner lock bolt and apply spring tension to belt.
b. Release ring gear brake.
c. Rotate timing belt pulley two complete revolutions in normal direction of rotation.
d. Align timing marks, then torque tensioner lock bolt to 28-38 ft.lbs. (38-53 N-m). If original timing belt is being reinstalled, measure belt deflection, Fig. 22. If deflection is not 0.47-0.55 inch (12-14 mm) for 1984-86 626 or 0.43-0.51 inch (11-13 mm) for 1986 B2000 and 1987 626, repeat tension adjustment procedure.
7. Install lower timing belt cover, then the upper cover using new gaskets. Torque attaching bolts to 5-7 ft.lbs. (7-10 N-m).
Fig. 22 Timing belt deflection check:
12 Valve Engine
1. Apply engine oil to front housing and a new oil seal.
2. Press oil seal into front housing.
3. Apply engine oil to oil seal lip, then install front housing with new gasket, torquing attaching bolt and nut to 14-19 ft.lbs. (19-25 N-m).
4. Install rear housing with new gasket, torquing attaching bolt to 14-19 ft.lbs. (19-25 N-m).
5. Apply suitable sealant as shown, Fig. 23, and install valve cover, torquing bolts to 52-69 inch lbs (6-8 N-m).
6. Install camshaft pulley on camshaft with dowel pin fit into hole at 1 mark, torquing attaching bolt to 35-48 ft.lbs. (47-65 N-m).
7. Align 1 mark on pulley with alignment mark on front housing.
8. Reverse direction of ring gear brake tool and install crankshaft key.
9. Install timing belt pulley on crankshaft, torquing to 116-123 ft.lbs. (157-167 N-m).
10. Release ring gear brake and align timing belt pulley and pump body alignment marks.
11. Install timing belt idler pulley, torquing to 27-38 ft.lbs. (37-52 N-m).
12. Install timing belt tensioner and spring and secure tensioner with spring fully extended.
13. Install timing belt so that there is no looseness at the water pump pulley and idler pulley side. If timing belt is being reused, it must be installed to rotate in original direction. Ensure there is no oil, grease or dirt on timing belt.
14. Loosen tensioner locknut, turn crankshaft two full rotations in direction of rotation and ensure timing marks are aligned. If not, remove belt and repeat installation procedure.
15. Torque timing belt tensioner lock bolt to 27-38 ft.lbs. (37-52 N-m).
16. Measure belt tension between crankshaft pulley and camshaft pulley. If deflection is not .030-.033 inch (7.5-8.5 mm) at 22 lbs., loosen tensioner locknut and repeat steps 14 and 15.
17. Position baffle plate on timing belt pulley and install timing belt covers with new gaskets, torquing to 61-87 inch lbs. (7-10 N-m).
18. Install crankshaft pulley.
FUEL PUMP & REAR HOUSING
1. Apply clean engine oil to fuel pump cam sliding surface.
2. Install fuel pump with insulator and two gaskets. Torque attaching bolt to 14-19 ft.lbs. (19-26 N-m).
3. Install rear housing assembly with a new gasket. Torque attaching bolts to 14-19 ft.lbs. (19-26 N-m).
4. Install crankshaft pulley and torque retaining bolt to specifications.
Fig. 23 Valve cover sealant application:
VALVE COVER
1. Position gasket on valve cover, then apply suitable sealant to areas indicated in Fig. 23.
2. Install valve cover and torque attaching bolts to specifications.
3. Install filler cap and ventilation hose.
FINAL ASSEMBLY
Exc. 12 Valve Engine
1. Install oil pressure switch and oil filter.
2. Install front and rear engine hangers, torquing attaching bolts to 14-22 ft.lbs. (19-30 N-m).
3. Install thermostat, then the thermostat cover with gasket, torquing attaching bolts to 14-22 ft.lbs. (19-30 N-m). Printed side of gasket must face thermostat.
4. Install upper radiator hose, ensuring matching marks are aligned.
5. Install distributor as follows:
a. Lubricate O-ring and drive gear with engine oil and position O-ring on distributor.
b. Match distributor housing and drive gear mating marks and install distributor into front housing with marks facing straight up.
c. Temporarily, loosely tighten distributor hold down bolt.
6. Apply small amount of anti-seize compound to first few threads of spark plugs and install plugs, torquing to 11-17 ft.lbs. (15-23 N-m), then connect spark plug wires.
7. Install intake manifold and carburetor assembly with new gaskets, torquing attaching bolts to 14-19 ft.lbs. (19-25 N-m).
8. Apply a coat of vegetable oil to coolant bypass hose O-ring and install coolant bypass hose, torquing to 14-22 ft.lbs. (19-30 N-m).
9. Install coolant inlet pipe and gasket, torquing to 14-19 ft.lbs. (19-25 N-m). Ensure there is no oil, grease or dirt on gaskets or contact surfaces.
10. Install lower radiator hose, ensuring matching marks align.
11. Install exhaust manifold and gasket, torquing to 16-21 ft.lbs. (22-28 N-m).
12. Install cooling fan bracket, torquing attaching bolts to 46-69 ft.lbs. (63-93 N-m).
13. Install alternator bracket, torquing attaching bolt to 27-46 ft.lbs. (37-63 N-m).
14. Install alternator, torquing alternator through bolt to 27-38 ft.lbs. (37-52 N-m) and the adjusting bolt to 23-34 ft.lbs. (31-46 N-m).
15. Install power steering pump and A/C compressor bracket(s), if equipped, torquing attaching bolts to 27-46 ft.lbs. (37-63 N-m).
16. Install engine mounts, torquing attaching bolts to 27-46 ft.lbs. (37-63 N-m).
12 Valve Engine
1. Install knock sensor, if equipped, and the oil pressure switch.
2. Install oil cooler, if equipped, torquing attaching bolts to 22-29 ft.lbs. (29-39 N-m), then install oil filter.
3. Install intake manifold assembly with new gasket, torquing attaching nuts to 14-22 ft.lbs. (19-30 N-m) in two or three steps.
4. Install intake manifold bracket, torquing attaching bolts to 14-22 ft.lbs. (19-30 N-m).
5. Install thermostat in cylinder head and position a new gasket with printed side facing cylinder head, then install thermostat cover, torquing to 14-22 ft.lbs. (19-30 N-m).
6. Apply anti-seize compound to spark plug threads and install plugs, torquing to 11-17 ft.lbs. (15-23 N-m).
7. Install distributor as follows:
a. Apply engine oil to O-ring and position it on distributor.
b. Apply engine oil to blade.
c. Install distributor into the rear housing.
d. Loosely tighten distributor hold down bolt.
8. Connect spark plug wires.
9. Install engine mount bracket, torquing attaching bolt to 63-86 ft.lbs. (85-117 N-m).
10. Install alternator strap and bracket, torquing to 27-46 ft.lbs. (37-63 N-m).
11. Install alternator and drive belt, adjusting belt tension and torquing alternator through bolt to 27-38 ft.lbs. (37-52 N-m) and the adjusting bolt to 23-34 ft.lbs. (31-46 N-m).
12. Install coolant inlet pipe, torquing to 14-19 ft.lbs. (19-25 N-m).
13. Apply vegetable oil to coolant bypass pipe O-ring, then install coolant bypass pipe, torquing to 27-46 ft.lbs. (37-63 N-m).
14. Install front and rear engine hangers, torquing to 14-22 ft.lbs. (19-30 N-m).
15. Install turbocharger bracket, if equipped, torquing to 27-38 ft.lbs. (37-52 N-m).
16. Place new exhaust manifold gasket in position with ridge facing cylinder head, then install exhaust manifold assembly, torquing attaching nuts to 16-21 ft.lbs. in two or three steps.
17. Attach turbocharger, if equipped, to bracket, torquing to 18-24 ft.lbs. (25-32 N-m).
18. Install oil pipe and turbocharger hose, if equipped, torquing side bolt to 16-20 ft.lbs. (22-27 N-m) and the rear bolt and the nut to 12-17 ft.lbs. (16-24 N-m).
19. Torque oil pipe bracket to 14-22 ft.lbs. (19-30 N-m), and connect oil hose and water hoses.
20. Install EGR pipe, torquing to 25-33 ft.lbs. (34-44 N-m).
21. Install exhaust manifold insulator, torquing to 14-22 ft.lbs. (19-30 N-m).
22. Install power steering pump bracket, torquing to 27-46 ft.lbs. (37-63 N-m).