Engine: Service and Repair

ENGINE OVERALL MOUNTING ENGINE ON
ENGINE STAND
1. Remove parts at the rear of the engine.
^ Transaxle assembly with starter motor
^ Clutch unit
2. Install engine attachment on the engine.
3. Place engine on work stand.





4. Drain engine oil and coolant.

OUTER PARTS
1. Parts at the rear of the engine
(1) Remove distributor together with high tension cables.
(2) Remove air injection pipe bracket and E.G.R. tube at E.G.R. valve side.





2. Parts on the left side of the engine
(1) Disconnect E.G.R. and air injection pipe.





(2) Remove exhaust manifold cover.
(3) Remove air injection pipe.
(4) Remove exhaust manifold.

Note: Exhaust manifold center nut has a different diameter from the other nut.





(5) Remove cooler compressor bracket and power steering pump bracket.
3. Parts on the right side of the engine
(1) Remove intake manifold with carburetor.





(2) Loosen water pump pulley bolts.
(3) Remove alternator, alternator bracket and drive belt.
(4) Remove oil filter.
(5) Remove oil pump assembly with gasket.
(6) Remove fuel pump assembly with spacer.

INTERNAL PARTS
1. Bottom parts
(1) Remove oil pan, gasket and oil seal.
(2) Remove oil strainer.
2. Rear side parts
(1) Remove thermostat housing.
(2) Remove flywheel or drive plate, then remove rear plate.

WARNING:
When removing flywheel, be careful not to drop it.





3. Front side parts
(1) Remove water pump pulley.
(2) Remove crankshaft pulley.





(3) Remove water pump assembly with gasket.





(4) Remove upper and lower dust cover.





(5) Remove tensioner pulley.





(6) Remove timing belt.

Note: Mark rotating direction mark on timing belt.

(7) Remove jack shaft pulley.
(8) Remove crankshaft timing pulley with spacer.

4. Separate cylinder head from cylinder block.
(1) Remove spark plugs.
(2) Remove valve rocker cover.
(3) Remove cylinder head bolts.

Note: The bolts should be loosened in two or three stages.





(4) Remove cylinder head assembly.





5. Jackshaft
(1) Remove front cover.

Caution: Be careful not to damage oil seal lip.





(2) Remove jack shaft locating plate.
(3) Take out jack shaft.
6. Piston and connecting rod assembly
(1) Remove connecting rod caps and bearings.
(2) Take out pistons together with connecting rods toward cylinder head side.





a. Piston can be easily removed by scraping carbon off top face of cylinder with a scraper.
b. Numbers are stamped on the connecting rod and cap corresponding to each cylinder. Care should be taken to avoid a wrong combination including bearing.
7. Crankshaft





(1) Remove oil seal retainer.
(2) Remove main bearing cap together with bearing.





(3) Remove crankshaft and bearings.

PISTON AND CONNECTING ROD
1. Remove piston rings.





Caution: Be careful not to scratch piston.

2. Press out piston pin.





Note: Keep disassembled parts in order.