Engine Disassembly and Assembly
DISASSEMBLYFig. 2 Crankshaft Pulley Removal:
Fig. 9 Timing Belt Removal:
Fig. 10 Timing Belt Sprocket Removal:
Fig. 11 Removing Crankshaft Timing Belt Pulley:
1. Drain engine oil.
2. Using Flywheel Holder 09924-17810, or equivalent, remove clutch cover attaching bolts, then clutch cover and disc.
3. Disconnect spark plug wires and vacuum hoses noting direction for installation, then remove distributor assembly.
4. Remove fuel pump attaching bolts, then fuel pump and rod.
5. Remove crankshaft pulley attaching bolts, then crankshaft pulley, Fig. 2. It is not necessary to remove crankshaft pulley center bolt.
6. Remove timing belt cover attaching bolts, then timing belt cover.
7. Loosen tensioner bolt and stud, then remove timing belt from crankshaft timing belt pulley by pushing upward on tensioner with finger, Fig. 9.
8. Remove timing belt tensioner, tensioner plate and spring.
9. Using camshaft holder tool No. 09917-68210 or equivalent, remove camshaft timing belt pulley, Fig. 10.
10. Using flywheel holder tool No. 09924-17810 or equivalent, so that crankshaft will not rotate, remove crankshaft timing belt pulley bolt, pulley and belt guide, Fig. 11.
11. Remove crankshaft timing belt pulley key from crankshaft.
12. Remove water pump attaching bolts, then water pump.
13. Remove exhaust manifold shield attaching bolts, then shield.
14. Remove exhaust manifold attaching bolts, then exhaust manifold.
15. Remove oil filter.
16. Remove hoses from water pump inlet pipe.
17. Disconnect positive PCV hose from valve cover.
18. Remove intake manifold attaching bolts, then intake and carburetor as an assembly.
19. Remove water pump inlet pipe attaching bolts, then inlet pipe.
20. Remove valve cover attaching bolts, then valve cover.
21. Loosen all valve adjusting screws and rocker arm shaft bolts, then pull out rocker arm shaft while separating rocker arms and springs.
22. Remove camshaft from rear of engine.
23. Remove cylinder head attaching bolts, then cylinder head.
24. Using a suitable spring compressor, compress valve springs and remove valve locks, then spring and valve.
25. Using a suitable screwdriver, remove valve stem oil seals from valve guides, then valve spring seats. Do not reuse oil seals after removal.
26. Using flywheel holder tool No. 09924-17810 or equivalent, remove flywheel attaching bolts, then flywheel.
27. Remove oil dipstick attaching bolt, then oil dipstick.
28. Remove oil pan attaching bolts, then oil pan.
29. Remove oil pump strainer attaching bolts, then oil pump strainer.
30. Remove connecting rod bearing cap bolts, then bearing caps noting direction for installation.
31. Decarbon top of each cylinder bore, before removing pistons from cylinder.
32. Remove piston and connecting rod assemblies out through top of cylinder bore. Before removing pistons, scribe cylinder number on top of pistons and ensure each bearing cap matches rod and piston assemblies for installation.
33. Remove oil pump attaching bolts, then oil pump and pump rotor plate.
34. Remove oil seal housing attaching bolts, then oil seal housing.
35. Remove crankshaft bearing cap bolts, then bearing caps noting direction for installation.
36. Remove crankshaft from cylinder block.
ASSEMBLY
1. Install selected main bearings into cylinder block, then lubricate bearings with oil. Ensure bearing half with oil hole passage is installed into cylinder block and other half without oil groove to bearing cap. Also ensure that both halves are painted with same color.
2. Install thrust washer to cylinder block between No. 2 and No. 3 cylinders. Ensure to face oil groove sides to crank webs.
3. Install crankshaft into cylinder block, then lubricate journals with oil.
4. Install bearing caps onto journals. Ensure that arrow on each cap is pointing towards crankshaft pulley. Torque cap bolts to specifications, starting from crankshaft pulley side, No. 1. After tightening cap bolts, ensure that crankshaft rotates smoothly when turned by hand.
5. Install oil seal housing and a new gasket. Apply oil to oil seal lip before installing. Torque bolts to specifications.
6. If oil pump was disassembled, assemble as follows:
a. Clean all components using a suitable solvent.
b. Lubricate inner and outer rotors, oil seal lip and inside surfaces of oil pump case and plate with engine oil.
c. Install outer and inner rotors into pump case.
d. Install gear plate. After installing gear plate, ensure that gears rotate smoothly by hand.
7. Install two oil pump pins and a new gasket onto cylinder block.
8. Install oil guide tool No. 09926-18210 or equivalent, onto crankshaft to prevent oil seal lip damage when installing oil pump assembly.
9. Install oil pump attaching pumps. Torque bolts to specifications.
Fig. 15 Piston Installation:
Fig. 24 Piston Pin Installation:
Fig. 25 Piston Ring Installation:
Fig. 26 Ring End Gap Alignment:
10. install piston rings onto piston as follows:
a. Apply engine oil to piston pin bores in piston and rod and fit connect rod to piston as shown in Fig. 15.
b. Place piston on tool No. 09910-38210 or equivalent so arrow mark on piston head faces up. Press piston pin into piston and connecting rod, Fig. 24.
c. Install piston second ring so marked side of second ring faces top of piston, Fig. 25. Note shape of of ring 2. The first ring has been modified. The stamp marking has been eliminated, therefore there is no longer a specified up or down direction.
d. Install oil ring spacer first, then two rails.
e. Align ring end gaps as shown in Fig. 26. Pistons and connecting rod assemblies must be installed in block so arrows on pistons face front (pulley end) of engine, Fig. 15.
11. Install connecting rod bearing caps. Torque cap nuts to specifications. Ensure that arrow (marked on each bearing cap) points towards crankshaft pulley side.
Fig. 27 Measuring Rod Bearing Side Clearance:
12. Using a suitable feeler gauge, measure side clearance of connecting rod big end, Fig. 27. Big end side clearance should be 0.0039-0.0078 inch (0.10-0.20mm), and must not exceed 0.0137 inch (0.35mm). If clearance exceeds limit, replace connecting rod.
13. Install oil pump strainer. Torque bolts to specifications.
14. Apply suitable sealant to oil pan, then install oil pan. Torque bolts, starting at center, to specifications.
15. Install gasket on drain plug, then drain plug into oil pan. Torque drain plug to specifications.
16. Install guide seal into oil pump case, then oil dipstick.
17. Install flywheel to crankshaft, then flywheel holder tool No. 09924-17810 or equivalent. Torque flywheel attaching bolts to specifications.
18. Install valve guides into cylinder head as follows:
a. Ream guide hole using a 12mm reamer, to remove any burrs. Ensure guide hole diameter is 0.4736-0.4743 inch (12.030-12.048mm) after reaming.
b. Heat cylinder head to approximately 176-212°F (80-100°C), then using tools Nos. 09917-88210 and 09916-57321 or equivalents, drive in new valve guide until valve guide protrudes 0.55 inch (14mm) from cylinder head.
c. Using a 7mm reamer, ream valve guide bore. After reaming, clean bore.
19. Install valve spring seat to cylinder head, then valve stem seal to valve guide.
20. Lubricate stem seal, valve guide bore and valve stem, then install valve into valve guide.
21. Install valve springs, then retainers using a suitable valve spring compressor. Ensure to install springs with bottom end (small pitch end) down to valve spring seat.
Fig. 28 Cylinder Head Tightening Sequence:
22. Install new head gasket, then cylinder head onto cylinder block. Torque bolts to specifications, as shown in Fig. 28.
23. Apply engine oil onto camshaft, then install camshaft from transmission case side.
Fig. 29 Intake & Exhaust Rocker Arm Shaft Identification:
24. Lubricate rocker arms and rocker arm shafts, then install rocker arms, springs and rocker shafts. Rocker arm shafts are not identical. Dimensions of their stepped ends differ as shown in Fig. 29. Install intake rocker arm shaft, facing stepped end to camshaft pulley side and exhaust rocker arm shaft, facing its stepped end to distributor side (rear side).
25. Torque rocker arms shaft screws to specifications.
26. Install water inlet pipe to cylinder block. Ensure to install new O-ring to inlet pipe before installing.
27. Install intake manifold with carburetor using a new gasket. Torque bolts to specifications.
28. Connect water hoses to water inlet pipe, and secure hoses with clamps.
29. Install oil filter.
30. Install exhaust manifold using a new gasket, and torque bolts to specifications.
31. Install water pump and new gasket. Torque bolts to specifications.
32. Install two rubber seats, one between oil pump and water pump and the other between water pump and cylinder head.
33. Install timing belt inside cover, then crankshaft timing belt guide, key and pulley. Torque timing belt pulley bolt to specifications.
34. Install camshaft timing belt pulley key, then pulley. Torque pulley bolt to specifications.
35. Install timing belt tensioner, tensioner plate and spring.
36. Refer to TIMING BELT, and install timing belt as outlined.
37. Install crankshaft pulley key, then crankshaft pulley. Torque pulley bolts to specifications.
38. Install alternator.
39. Install distributor case 0-ring to cylinder block, then distributor case. Torque bolts to specifications. After tightening distributor case, fill distributor case with approximately 1 ounce of engine oil.
40. Install fuel pump rod, gasket and fuel pump onto cylinder head. Lubricate rod with engine oil before installing.
41. Install clutch disc and cover using alignment tool No. 09923-38220 or equivalent, and torque bolts to specifications.
42. Install transmission assembly onto engine. Torque bolts to specifications.
43. Install distributor assembly into distributor case, then connect spark plug wires.
44. Refer to Engine/Cylinder Head Assembly/Valve, Intake/Exhaust/Adjustments, and adjust valve clearance as outlined.
45. Install valve cover. Torque bolts to specifications and check ignition timing.