Cylinder Block Assembly: Service and Repair

Cylinder Block
Removal






1. Remove distributor and plug cord.
2. Loosen water pump pulley mounting nuts or bolts.
3. Remove alternator and V-belt. [Except air conditioner equipped model]
4. Remove EGR pipe cover and EGR pipe.
5. Removal of intake manifold ASSY
(a) Remove hoses and tubes from cylinder block side.
(b) Disconnect each harness.
(c) Remove intake manifold ASSY from engine.
6. Remove power steering oil pump bracket from cylinder lock. [Power steering model]
7. Remove alternator brackets and adjusting bar. [All except air-conditioner models]
8. Remove knock sensor. [TURBO model]
9. Remove air bleed hose.
10. Remove oil filler duct.
11. Remove water pipe.











12. Remove crankshaft pulley. To lock crankshaft, use FLYWHEEL STOPPER (498277000) [manual transmission model] or DRIVE PLATE STOPPER (498497000) [automatic transmission model].






13. Remove water pump pulley and pulley cover.
14. Remove oil level gauge guide together with gauge.
15. Remove timing belt, belt cover and related parts. (Refer to "Timing Belt and Belt Cover".) Service and Repair
16. Remove water pump together with hose and pipe.
17. Remove oil pump by aligning notch in oil pump pulley with bolt position, then remove pump outer rotor from cylinder block.
18. Removing clutch cover and clutch disc. [All except automatic transmission model] Be careful not to let oil, grease or coolant contact the clutch disc.
19. Remove flywheel [manual transmission model] or drive plate [automatic transmission model], and take out flywheel housing with housing cover. To lock crankshaft, use FLYWHEEL STOPPER (498277000) or DRIVE PLATE STOPPER 498497000).
20. Remove camshaft, valve rocker and related parts. (Refer to "Camshaft and Valve Rocker".)
21. Remove TURBO cooling pipe together with union screws and gaskets from cylinder head. [TURBO model]
22. Remove cylinder heads and gaskets.
23. Remove of pan.
24. Remove oil strainer and strainer stays.

DISASSEMBLY
1. Remove oil separator cover.
2. Remove service hole plugs from cylinder block using hexagon wrench (14 mm).
3. Rotate crankshaft to bring #1 and #2 pistons to TDC position.






4. Remove piston circlip through service hole of #1 and #2 cylinders.






5. Draw out piston pin from #1 and #2 pistons using PISTON PIN REMOVER (399094310).
6. Similarly remove piston pins from #3 and #4 pistons. Be careful not to confuse original combination of piston, piston pin and cylinder.
7. Remove all of cylinder block connecting bolts except one 10-mm bolt under center journal. Loosen this 10-mm bolt until it can be turned by hand. (Cylinder block connecting bolts: six 10-mm bolts and six 8-mm bolts.)
8. Set up cylinder block so that #1 and #3 cylinders are on the upper side, then separate left-hand and right-hand cylinder blocks. When separating cylinder block, do not allow the connecting rod to fall and damage the cylinder block.






9. Remove coolant passage 0-ring and back-up ring from left-hand cylinder block.
10. Remove front oil seal and rear oil seal from crankshaft.
11. Remove crankshaft together with connecting rod from cylinder block.
12. Draw out each piston from cylinder block using wooden bar or hammer handle. Do not confuse combination of piston and cylinder.






13. Remove crankshaft bearings from cylinder block using hammer handle.
a. Do not confuse combination of crankshaft bearings. Press bearing at the end opposite to locking lip.
b. Do not confuse combination of crankshaft bearings.

INSPECTION
CYLINDER BLOCK
Check cylinder block for the following items, and correct or replace if defective.
1. Check for cracks and damage visually. Especially, inspect important parts by means of red check.
2. Check the oil passages for clogging.
3. Inspect the crankcase surface that mates with cylinder head for warping by using a straight edge, and correct by grinding if necessary.
Warping limit: 0.05 mm (0.0020 in)
Grinding limit: 0.4 mm (0.016 in).

CYLINDER AND PISTON











1. Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights shown in the figure, using a cylinder bore gauge. Measurement should be performed at a temperature of 20°C (68° F). 1800cc 33.5 mm (1.319 in).

2. Boring and Honing






(a) If the value of taper, out-of-roundness, or cylinder-to-piston clearance measured exceeds the specified limit or if there is any damage on the cylinder wall, rebore it to use an oversize piston. Measurement should be performed at a temperature of 20° F (68° C). When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and use oversize pistons. Do not perform boring fin one cylinder only, nor use an oversize piston for one cylinder only.
(b) Get four of the oversize pistons and measure the outer diameter of each piston at the height shown in the figure. (Thrust direction)











Piston outer diameter:
Standard
Non-TURBO
91.970 - 91.980 mm (3.6209 - 3.6213 in).
TURBO
91.975 - 91.985 mm (3.6211 - 3.6214 in). 0.25 mm (0.0098 in) oversize.
Non-TURBO
92.220 - 92.230 mm (3.6307 - 3.6311 in).
TURBO
92.225 - 92.235 mm (3.6309 - 3.6313 in). 0.50 mm (0.0197 in) oversize.
Non-TURBO
92.470 - 92.480 mm (3.6405 - 3.6409 in).
TURBO
92.475 - 92.485 mm (3.6407 - 3.6411 in).
(c) If the cylinder inner diameter exceeds the following enlarging limit after boring and honing, replace the crankcase. Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, pay attention to this when measuring the cylinder diameter.
Enlarging limit of cylinder inner diameter: 0.30 mm (0.0118 in).
(d) Inspect the cylinder bore for taper, out of-roundness, and diameter differences.
Diameter difference between cylinders: Measure the inner diameter of the cylinder when the temperature is 20°C (68° F). 0.050 mm (0.0020 in) or less.

ASSEMBLY
1. Install ENGINE STANDS (499817000) to cylinder blocks. When installing ENGINE STANDS, fit bolts to the holes marked with "R" on the #1 and #3 cylinder sides, and to the holes marked with "L" on the #2 and #4 cylinder sides.
2. Install crankshaft bearings to cylinder blocks.
3. Install crankshaft to left-hand cylinder block.
4. Fit 0-ring and back-up ring to coolant passage of left-hand cylinder block.






5 Apply fluid packing (Three-bond 1215, or equivalent) to 0.30 mm (0.0118 in).











6. With left-hand cylinder block facing down, install right-hand cylinder block. After tightening bolts temporarily, lay cylinder block down, then tighten bolts to the specified torque. Make sure 0-ring is fitted correctly in groove.
Tightening torque:
10 mm bolt: 39 - 47 N.m (4.0 - 4.8 kg-m, 29 - 35 ft-lb).
8 mm bolt: 23 - 26 N.m (2.3 - 2.7 kg-m, 17 - 20 ft-lb).
7. Check thrust clearance of crankshaft.
Thrust clearance:
Standard: 0.010 - 0.095 mm (0.0004 - 0.0037 in
Limit: 0.3 mm (0.012 in.)






8. Position the gaps of the piston rings and oil ring as shown in the figure.
9. Install pistons in cylinder as follows.
(a) Apply oil to the circumference of piston and the inner surface of cylinder.
(b) With the #3 and #4 cylinders facing downwards, turn crankshaft until the #1 and #2 connecting rod comes to the bottom dead center. Then insert the #1 and #2 piston into cylinder by using PISTON GUIDE (398744300).






(c) Install piston pin and circlip through the service hole after aligning the service hole, piston pin hole, and connecting rod small end with PISTON PIN GUIDE (399284300). Circlip must be installed in correct direction with its end facing out. PISTON PIN GUIDE (399284300).
(d) With #1 and #2 cylinders facing down, turn crankshaft until #3 and #4 piston connecting rods are at the bottom dead center position. Similarly to #1 and #2 cylinders, install pistons, piston pins, and circlips to #3 and #4 connecting rods. Install crankshaft bolt to turn crankshaft.
(e) Turn crankshaft, and check whether pistons are assembled correctly.
10. Apply fluid packing (Fuji-bond C, or equivalent) to plugs, and tighten it with aluminium gasket placed in between. the service hole, piston pin hole, and connecting rod small end with PISTON PIN GUIDE (399284300).
Tightening torque: 62-76 N.m (6.3 - 7.7 kg-m, 46 - 56 ft-lb).






11. Install rear oil seal to cylinder block using INSTALLER (499587000). Coat oil seal lips with grease. Coat the outside surface of oil seal with engine oil.
Max. allowable out-of-squareness of oil seal: 0.3 mm (0.012 in).
12. Install oil separator cover with gasket placed in between.
Tightening torque: 4.4 - 5.4 N.m (0.45 - 0.55 kg-m, 3.3 - 4.0 ft-lb).






13. Install front oil seal to cylinder block using OIL SEAL INSTALLER (499567000). Coat the outside surface of oil seal with engine oil, and oil seal lip with grease. Force-fit oil seal squarely into position.
Max. allowable out-of-squareness of oil seal: 0.2 mm (0.008 in.)

INSTALLATION
1. secure oil strainer to cylinder block with oil strainer stays.
2. Install oil pan.
Tightening torque: 4.4 - 5.4 N.m (0.45 - 0.55 kg-m, 3.3 - 4.0 ft-lb).

Cylinder Head:

3. Install cylinder heads to cylinder blocks with gaskets placed between. When tightening bolts, apply oil to the threads and tighten them in two or three successive steps until the final tightening is at the specified torque. In each step, tighten them in the specified sequence.
1st step: 29 N.m (3.0 kg-m, 22 ft-lb).
2nd step: 59 N.m (6.0 kg-m, 43 ft-lb).
3rd (final) step: 64 N-m (6.5 kg-m, 47 ft-lb).
See TSB 02-85-91.
4. Install TURBO cooling pipe together with union screws and gaskets to cylinder head.
Tightening torque: 21.1 - 24.0 N.m (2.15-2.45 kg-m, 15.6 - 17.7 ft-lb).
5. Install flywheel housing with housing cover and pitching stopper bracket.
Tightening torque: 34 - 40 N.m (3.5 - 4.1 kg-m, 25 - 30 ft-lb).
6. Install flywheel to crankshaft using FLYWHEEL STOPPER (498277000) for locking crankshaft. (Manual transmission model]
Tightening torque: 69 - 75 N.m (7.0 - 7.6 kg-m, 51 - 55 ft-lb).
7. Install drive plate and reinforcement using DRIVE PLATE STOPPER (498497000) for locking crankshaft. [Automatic transmission model]
Tightening torque: 69 - 75 N.m (7.0 - 7.6 kg-m, 51 - 55 ft-lb).
8. Position the clutch cover so that the " 0 ", marks on the flywheel and clutch cover are spaced 120° or more. Install clutch disc and clutch cover with bolts and spring washers, aligning clutch disc with flywheel by inserting CLUTCH DISC GUIDE (499747000) into needle bearing fitted in flywheel. [Manual transmission model].
Tightening torque: 16 N.m (1.6 kg-m, 12 ft-lb).
9. Install seal to water pump, then install the water pump to cylinder block with gasket placed between.






10. Install oil pump ASSY, proceeding as follows:
(a) Thoroughly remove excess fluid packing from rotor housing of cylinder block.
(b) Apply a small amount of fluid packing (Three-bond 1215, or equivalent) to the portion indicated by arrow in Figure in cylinder block.
(c) Apply ample engine oil to rotor housing, then insert outer rotor into rotor housing by setting it as shown.
(d) Set oil pump pulley as shown, and install oil pump ASSY to cylinder block with gasket placed between. After installing, make sure pulley can be rotated smoothly.
(e) Install oil pressure switch or oil pressure gauge to oil pump ASSY. Loosen oil pressure gauge lead clamping screw and route the lead on the side of #1 and #3 cylinders.
Tightening torque: 22 - 27 N.m (2.7 - 2.8 kg-m, 16 - 20 ft-lb).






11. Insert valve lash adjusters into cylinder head. Be sure to insert each valve lash adjuster to its original position.
12. Apply grease to spherical surface and sliding surface of each valve rocker, then secure valve rockers to the respective valve adjusters and valves. Be sure to apply grease; otherwise, valve rocker will drop off.






13. Install 0-ring to camshaft case by setting camshaft so that camshaft straight pin is oriented as shown.






14. Apply fluid packing (Three-bond 1215, or equivalent) to groove of each camshaft case, then install to cylinder head. After installing, abundantly apply engine oil to sliding surfaces of cam and valve rocker.
Tightening torque: 17.2 - 20.1 N.m (1.75-2.05 kg-m, 12.7 - 14.8 ft-lb).
15. Attach gaskets to valve rocker covers, and install the covers to camshaft cases with rocker cover washers and bolts. Be extremely careful not to cause oil to leak from mating faces of valve rocker cover and camshaft case.
Tightening torque: 4.4 - 5.4 N.m (0.45-0.55 kg-m, 3.3 - 4.0 ft-lb).
16. Install timing belt, belt cover and related parts. (Refer to "Timing Belt and Belt Cover".)
17. Install crank pulley to crankshaft using FLYWHEEL STOPPER (498277000) [manual transmission model] or DRIVE PLATE STOPPER (498497000) [automatic transmission model] to lock crankshaft.
Tightening torque: 89 - 107 N.m (9.1 - 10.9 kg-m, 66 - 79 ft-lb).
18. Install water pump pulley and pulley cover to water pump ASSY, and tighten bolts temporarily.
19. Install oil level gauge and gauge guide. Apply engine oil to 0-ring beforehand.
20. Install oil filler duct and bracket.
21. Install water bypass pipe, hose, and water pipe. Apply coolant to 0-rings beforehand.
22. Install knock sensor. [TURBO model]
Tightening torque: 22 - 27 N.m (2.2 - 2.8 kg-m, 16 - 20 ft-lb).
23. Install air bleed hose.






24. Install alternator bracket, proceeding as follows. [All except air conditioner model].

(a) Assemble bracket (A) and bracket (B) temporarily with bolt (C) so that these two parts contact each other.
(b) Install assembled brackets (A) and (B) to engine, and hand-tighten bolts (E) and (D).
(c) Tighten bolt (D) to the specified torque, then tighten bolt )E) to the specified torque.
(d) Tighten bolt (C) to the specified torque.
Tightening torque:
Bolt (C)
16 - 22 N.m (1.6 - 2.2 kg-m, 12 - 16 ft-lb).
Bolts (D) and (E)
36 - 42 N.m (3.7 - 4.3 kg-m, 27 - 31 ft-lb).
25. Install power steering oil pump bracket to cylinder block. [Power steering model]
26. Install intake manifold and EGR pipe to engine, then fit EGR pipe cover.
Tightening torque:
Intake manifold
18 - 22 N.m (1.8 - 2.2 kg-m, 13 - 16 ft-lb).
EGR pipe plug
31 - 37 N.m (3.2 - 3.8 kq-m, 23 - 27 ft-lb).
27. Install harnesses.
28. Install hoses and tubes.
29. Install alternator to bracket, and tighten bolts temporarily. [Except air conditioner model].
30. Install distributor, proceeding as follows:
(a) Bring #1 cylinder piston to its top dead center on compression stroke. Set camshaft sprocket to the position shown in Figure.
(b) Align distributor housing match mark with pinion gear match mark to set #1 cylinder at igniting position.
(c) Install distributor to camshaft case.
(d) Connect lead wires.
(e) Install plug cord and high-tension cord.
31. Install right and left belt covers.
32. Remove ENGINE STAND.
33. Install front exhaust pipe to cylinder head. [TURBO model].
34. Install turbocharger and TURBO cooling hose. [TURBO model].
35. Install air duct and boots. After completing engine ASSY and mounting engine on car, be sure to retighten cylinder head bolts.

RETORQUING
1. Warm up engine.
2. After engine has cooled down, remove right and left valve rocker covers.
3. Loosen intake manifold (No.1 and No.3 cylinders side) mounting bolts (three) by 60°. Do not loosen mounting bolts of manifold for No.2 and No.4 cylinders.
Do not loosen the mounting bolts mare than 90°, or water. may leak.











4. Loosen bolt at position #1 in Figure, and apply oil to the thread. Repeat "loosen and tighten" operation four to five times within the 60° range for a better fit, then tighten bolt to the specified torque.






Specified torque:
64 N.m (6.5 kg-m, 47 ft-lb).






5. Similarly, retighten each bolt in the sequence from #2 to #9 as shown in Figure
Finally, retighten bolt #1 to the specified torque without loosening.
6. After retightening right and left cylinder head bolts, tighten six mounting bolts of intake manifolds (No.1 and No.3) (No.2 and No.4).