Assembly

1. Install engine stands onto each crankcase half.
2. Apply sealant to oil pressure switch threads and torque switch to 16-20 ft.lbs.
3. Check that oil passages are clear using compressed air.
4. Install crankshaft bearings into crankcase.
5. Install valve lifters into lifter holes in case. Apply engine oil to lifters prior to installation.
6. Install camshaft and crankshaft into the No. 2 and 4 cylinder crankcase half. Apply engine oil to the crankshaft and camshaft bearings prior to installation.
7. Install the O-ring and back-up ring into the No. 2 and 4 cylinder crankcase half.

Fig. 9 Aligning camshaft & crankshaft gears. 4-97/1600cc & 1984 4-109/1800cc engines:

8. Align crankshaft and camshaft gears, Fig. 9.
9. Apply liquid sealant to the mating surfaces of crankcase halves.
10. Install valve lifter clips 899804100 between the valve lifters in the No. 1 and 3 cylinders crankcase to prevent lifters from dropping off.

Fig. 10 Crankcase bolt tightening sequence:

11. Position crankcase halves together and torque retaining bolts and nuts to 29-35 ft.lbs. for 10 mm thread sizes, 17-20 ft.lbs. for 8 mm thread sizes, and 3.3-4.0 ft.lbs. for 6 mm thread sizes. Follow sequence in Fig. 10. Check that O-ring is installed correctly. On 4 wheel drive vehicles, install stiffener temporarily.
12. Install camshaft plate onto crankcase with two lockwashers and bolts. Bend lockwashers to secure bolts.
13. To install pistons, proceed as follows:
a. Apply oil to piston's circumference and cylinder walls.
b. With cylinders No. 2 and 4 facing downward, rotate crankshaft until No. 2 connecting rod is positioned at BDC.
c. Install No. 2 piston using tool 398744300 and a suitable soft faced hammer.

Fig. 11 Service hole location & piston pin guide tool:

14. Install piston pin and circlip through front service hole after aligning the service hole, piston pin hole, and connecting rod small end using tool 399284300, Fig. 11.
15. Install circlip using long needle nosed pliers.
16. Install No. 4 piston, piston pin, and circlip into cylinder in same manner as described previously. The service hole for cylinder No. 4 is on the flywheel housing side.
17. Position crankcase so that cylinders No. 1 and 3 face downward. Install pistons for these cylinders in same manner as described previously.
18. Rotate crankshaft to check that piston pins are correctly installed.
19. Apply liquid gasket to the crankcase plugs. Install aluminum gasket and torque the plugs to 46-56 ft.lbs.
20. If strainer was removed, reinstall with new O-ring.
21. nstall oil strainer stay and torque retaining bolt to 17-20 ft.lbs.
22. Clean mating surfaces of cylinder head and crankcase. Apply head gasket sealant to both sides of new cylinder head gasket.

Fig. 12 Cylinder head installation position. 4-97/1600cc & 4-109/1800cc engines:

23. Install No. 2 and 4 cylinder head and align pushrods with valve lifters, Fig. 12.
24. Install valve rocker.

Fig. 13 Cylinder head tightening sequence. 4-97/1600cc & 1984 4-109/1800cc engines:

25. Apply oil to cylinder head stud and bolt threads and torque them in correct sequence in three steps, Fig. 13. The first torque step is 22 ft.lbs. The second step is 43 ft.lbs. The final step is 47 ft.lbs. Use wrench 499987006 to torque nuts No. 1 and 9.
26. Torque 6 mm bolts to 6.5-8.0 ft.lbs., after seven nuts and two bolts in sequence to their final specified torque.
27. Install No. 1 and 3 cylinder head using the same procedure as described previously.
28. If rear oil seal has been removed, press it back into the flywheel housing. Apply oil to circumference prior to installation.
29. Apply sealant to flywheel housing mating surfaces and torque retaining bolts to 14-20 ft.lbs.
30. Remove valve lifter retaining clips prior to installing oil pan.
31. Install crankcase oil pan, pan gasket, and transmission cover. Torque retaining bolts to 3.3-4.0 ft.lbs.
32. Install pitching stopper bracket and crankcase rear hanger to flywheel housing. On 4 wheel drive vehicles, install fuel pipe stay and pitching stopper bracket to the flywheel housing.
33. Apply sealant to flywheel or converter drive plate with back plate retaining bolt threads.
34. On manual transmission models, torque the flywheel retaining bolts to 30-33 ft.lbs.
35. On automatic transmission models, torque the drive plate to 36-39 ft.lbs. The flywheel can only be installed in one position because retaining bolt holes are not positioned at equal intervals. When installing the back plate, align the mark on the back plate and the hole in the drive plate. Apply grease to the crankshaft needle bearing.
36. On all models, position tool 399740100 into clutch disc and cover. Install disc and cover using tool to align disc and crankshaft. Position tool into crankshaft needle bearing and then remove the tool. Position clutch cover so that ``0'' mark on flywheel and clutch cover are at least 120° apart.
37. Install water pump, heater pipe and hoses as an assembly.
38. Install oil filter onto oil pump assembly.
39. nstall oil pump assembly O-ring and gasket between crankcase and pump assembly.
40. Install pump assembly and torque retaining bolts to 15.9-20.3 ft.lbs.
41. Install front oil seal using tool 499067000 and a suitable soft faced hammer.
42. Install front crankshaft pulley and torque retaining bolt to 47-54 ft.lbs. To prevent the crankshaft from rotating during tightening, insert a suitable screwdriver into the timing hole and into a hole in either the flywheel or drive plate.
43. Install oil filler duct, stay and gasket onto crankcase. On 4 wheel drive models, install the oil filler duct, stiffener, and gasket on the crankcase.
44. Tighten alternator bracket retaining bolts until spring washer is slightly deformed. Back off retaining bolts, then torque to 9-14 ft.lbs.
45. To adjust valve clearances, proceed as follows:
a. Position piston into cylinder to be checked at TDC on compression stroke.
b. Insert feeler gauge between valve stem and rocker arm to measure clearance.
c. Loosen locknuts and rotate adjustment screw to obtain specified valve clearance. Adjust the clearances when the engine is cold. If the adjustment is made during the first service interval, re-torque the cylinder head retaining nuts and bolts prior to adjustment.
46. Install valve rocker covers, gaskets, and seal washers. Torque retaining bolts to 2.2-2.9 ft.lbs.
47. Torque spark plugs to specified torque value.
48. To install intake manifold proceed as follows:
a. Install intake manifold assembly, intake manifold gasket, air cleaner bracket, fuel hose bracket, and EGR pipe.
b. Connect water bypass hoses, oil pressure switch or gauge electrical connections, and PCV hose to the rocker cover. Check that the electronic control unit ground is connected to left rear bolt.
49. Install EGR pipes into cylinder heads.
50. Reverse remaining procedure to complete installation.