Disassembly

1. On carbureted engines, proceed as follows:
a. Remove carburetor protector, if equipped, mount engine in suitable stands, drain coolant and engine oil, then reinstall drain plugs.
b. Disconnect high tension leads from spark plugs and ignition coil, then separate leads from retaining clips.
c. Disconnect vacuum and PCV hoses, then remove distributor and hold down plate.
d. On models less A/C, loosen water pump pulley nut, then remove alternator mounting bolts and the alternator, along with air cleaner and plug wire brackets.
e. Remove silencers, Air Switching Valve (ASV) and ASV pipes, as equipped, then the EGR cover.
f. Remove battery cable, ASV and power steering pump brackets, as equipped, then the EGR pipe.
g. Disconnect and remove crankcase ventilation and coolant hoses, noting position for assembly.
h. Disconnect engine harness electrical connectors noting position for installation, then remove harness.
i. Remove intake manifold retaining nuts and washers, then the manifold.
2. On fuel injected and turbocharged engines, proceed as follows:
a. Remove air intake duct.
b. On turbocharged models, disconnect coolant hoses from turbocharger, then remove turbocharger and front exhaust pipe.
c. On all models, mount engine in suitable stands, drain coolant and engine oil, then reinstall drain plugs.
d. Disconnect high tension leads from spark plugs and ignition coil, and remove leads from support bracket.
e. Remove PCV and distributor vacuum hoses, wiring harness clips and ground terminal fastener, disconnect connectors and remove wiring harness.
f. Remove hold down bolts and the distributor.
g. On models less A/C, loosen water pump pulley nut, then remove alternator and drive belt.
h. Disconnect electrical connector from oil pressure switch and air bleed hose from intake manifold.
i. Remove EGR pipe clamps, EGR cover and the EGR pipe.
j. Remove intake manifold assembly.
3. Remove power steering pump and alternator brackets.
4. On turbocharged models, remove knock sensor.
5. Remove fuel injectors, if equipped.
6. On all models, remove oil filler pipe, water pipes and air bleed hoses. On 4 wheel drive vehicles, remove the stiffener.

Fig. 2 Crankshaft, flywheel & converter drive plate assembly. 4-97/1600cc & 1984 4-109/1800cc engines:

7. Remove crankshaft pulley bolt, Fig. 2. To prevent crank from turning, insert a screwdriver through the timing hole.
8. Remove crankshaft pulley by tapping it lightly with a suitable soft-faced hammer.
9. Remove oil pump and filter assembly.

Fig. 14 Cylinder block assembly. 4-109/1800cc SOHC engine:

10. Remove water pump pulley and pulley cover.
11. Remove dipstick and dipstick tube, Fig. 14.

Fig. 15 Timing belt cover assembly. 1985-94 4-109/1800cc engine:

12. Remove timing belt cover plate (Turbo models), then the left and right front timing belt covers, Fig. 15.

Fig. 16 Camshaft & belt drive installation. 1985-88 4-109/1800cc engine:

13. Loosen bolts securing timing belt tensioner to No. 1 cylinder, rotate tensioner to fully released position, then retighten bolts, Fig. 16.
14. Mark rotational direction, then remove timing belt.
15. Loosen bolts securing tensioner 2 to No. 2 cylinder, rotate tensioner to fully relaxed position using wrench 499007000 or equivalent, then retighten bolts.
16. Remove first crankshaft sprocket.
17. Mark rotational direction of remaining belt, then remove belt and second crankshaft sprocket.
18. Remove both belt tensioner assemblies along with tensioner springs.
19. Secure camshaft sprockets with suitable wrench, then remove sprocket retaining bolts and the sprockets.
20. Remove remaining timing belt covers.
21. Remove water pump, hose and pipe as an assembly.
22. Align oil pump sprocket notch with retaining bolt, then remove bolts and pump rotor assembly from cylinder block.
23. Remove clutch assembly and flywheel or automatic transmission flex plate, as equipped, then the flywheel housing.
24. Remove spark plugs, camshaft covers and cover gaskets.
25. Evenly loosen bolts securing camshaft cases, then remove case, camshaft support and camshaft assemblies.
26. Remove rocker arms and hydraulic lifters, keeping components in proper order for assembly. Do not store lifters on their sides; keep them upright.
27. On turbocharged models, remove turbocharger cooling pipe, union and gasket from cylinder head.
28. Remove cylinder head retaining bolts and the cylinder heads.
29. Remove service access plugs from cylinder block, then rotate crankshaft to bring Nos. 1 and 2 pistons to BDC.
30. Remove piston pin retainers through service openings, then withdraw piston pins using suitable remover.
31. Rotate crankshaft to position Nos. 3 and 4 pistons at BDC, then remove piston pin retainers and piston pins.
32. Remove all cylinder block retaining bolts except 10 mm bolt under center crankshaft journal, and loosen the 10 mm bolt until it can be turned by hand.

Fig. 14 Cylinder block assembly. 4-109/1800cc SOHC engine:

33. Position cylinder block assembly with cylinders No. 3 and 4 facing up, then separate left and right halves of block, Fig. 14.
34. Remove coolant passage O-ring and back-up ring from LH cylinder block, and front and rear oil seals from crankshaft.
35. Remove crankshaft and connecting rod assembly.
36. Mark and remove pistons from cylinder block halves, and mate pistons with respective pins. Keep all components in order to ensure proper assembly. Components that are to be reused should be installed in original position.
37. Remove main bearings from crankcase halves.
38. Remove oil relief plug, oil relief pipe and spring and the oil relief valve from camshaft case.