NISSAN PULSAR 1987 Repair Manual
Manufacturer: NISSAN, Model Year: 1987, Model line: PULSAR, Model: NISSAN PULSAR 1987Pages: 238, PDF Size: 28.91 MB
Page 51 of 238
Engine 51
coolant temperature sensor and temperature sender
switch located in the thermostat housing.
(8) Remove the bolt securing the wiring clamp
to the rear of the manifold and maneuver the wiring
away from the cylinder head and the inlet manifold.
(9) Disconnect the throttle cable and on auto-
matic transaxle models, the kickdown cable from the
throttle body linkage. (10) Remove the bolls securing the throttle cable
bracket to the inlet manifold and place the bracket
and cable(s) to one side.
(11) Mark the fuel supply and return hoses to
ensure correct installation and disconnect the hoses
from the fuel rail or throttle body. Plug the hoses to
prevent the loss of fuel or the entry of dirt. (12) Mark the vacuum hoses connected to the
inlet manifold and throttle body to ensure correct
installation and disconnect the hoses. (13) Remove the nuts securing the engine pipe to
the exhaust manifold and separate the pipe from the
manifold. (14) Remove the oxygen sensor from the exhaust
manifold. Refer to the Fuel and Engine Management
section if necessary. (15) Remove the distributor and coil as described
in the Fuel and Engine Management section. (16) Disconnect the engine breather hoses from
the camshaft housing and cams haft housing top cover.
(17) Remove the bolts retaining the top cover to
the camshaft housing and remove the top cover. (18) Using an open end spanner, hold the cam-
shaft between the inlet and exhaust lobes of number
four cylinder and remove the camshaft timing gear
retaining bolt and the camshaft timing gear.
(19) Remove the bolts securing the camshaft
drive belt inner cover to the camshaft housing. (20) Loosen the cylinder head bolts in the reverse
order of the tightening sequence, backing off each bolt
a quarter turn then half a turn at a time until the bolts
are loose.
NOTE: Do not loosen the head bolts while
the engine is warm as distortion of the
cylinder head could result.
(21) Remove the cylinder head bolts and lift the
camshaft housing from the cylinder head. (22) Remove the cylinder head and gasket from
the cylinder block. Installation is a reversal of the removal procedure
with attention to the following points:
(1) Thoroughly clean the gasket surfaces of the
cylinder head, cylinder block and camshaft housing
and check all mating surfaces with a straight edge.
Ensure that all the oilways are clean and free of any
foreign material and lightly oil all operating parts with
engine oil.
(2) Install new gaskets throughout during
assem-
bly.
View of the cylinder head showing the bolt tightening
sequence.
(3) Ensure that the cylinde r head and gasket are
located correctly on the dowels on the cylinder block
face. The head gasket is marked TOP to aid in correct
installation. (4) With the cylinder head and gasket in posi-
tion on the cylinder block, apply an even smear of
Loctite 515 to the cylinder head and camshaft housing
mating surfaces. Take care that no sealant is forced
into the oil passages. (5) Install new cylinder head bolts and lubricate
the bolts and washers with engine oil,
(6) Apply an initial torque to the cylinder head
bolts of 25 Nm in the sequence shown in the
illustration. Further tighten the head bolts in the same
sequence in three separate 60 degree stages. Refer to
Specifications. (7) Install the bolts secur ing the camshaft drive
belt inner cover to the camshaft housing. Install the
camshaft timing gear and tighten the retaining bolt to
the specified torque. (8) Install and adjust the camshaft drive belt as
previously described. (9) Install the distributor, coil and oxygen sensor
as described in the Fuel and Engine Management
section.
(10) Using a new gasket, connect the engine pipe
to the exhaust manifold flange, coat the nuts with an
anti-seize compound and install and tighten the nuts
to
the specified torque. (11) Connect all hoses and electrical wiring dis-
connected during the removal of the cylinder head.
Ensure that all the hoses are returned to their original
locations. (12) Connect the throttle cable and where appli-
cable, the kickdown cable. Adjust the cables as
described in the Fuel and Engine Management section
and the Automatic Transaxle section. (13) Check the engine oil fo r correct level on the
dipstick and for dilution. Change the engine oil and
filter if necessary. (14) Fill the cooling system as described in the
Cooling and Heating Systems section. (15) Start the engine and check for oil or water
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52 Engine
leaks and rectify as necessary. Check and if necessary
adjust the ignition timing as described in the Engine
Tune-up section.
(16) When the engine has reached normal oper-
ating temperature, tighten the cylinder head bolts
another 40-50 degrees in the correct sequence shown
in the illustration, ensuring that the tension does not
exceed 135 Nm.
TO DISMANTLE
(1) Remove the cylinder head as previously
described.
(2) Remove the thermostat housing and sealing
ring from the cylinder head.
(3) Remove the nuts securing the inlet and
exhaust manifolds to the cylinder head and remove
the manifolds. Discard the gaskets. (4) Lift the rocker arm and thrust pad from the
top of each valve assembly, keeping them in order for
assembly to their or iginal locations.
(5) Slide each hydraulic tappet from its bore in
the cylinder head, also keeping them in order for
assembly to their or iginal locations.
(6) Before removing the valves the deposits in
Installed view of the cylinder head oil pressure relief
valve.
the combustion chambers s hould be removed. Care
should be taken not to damage the cylinder head
gasket face.
(7) Using a valve spring compressor, compress
each spring in turn. Remove the split retaining collets
and slowly release the compressor.
(8) Remove the valve spring retainers and valve
springs. (9) Remove the valve stem seals from the top of
the valve guides and detach the exhaust valve rotators
and the inlet valve spring seats, from the cylinder
head. (10) Remove any burrs from the valve stem
grooves to prevent damage to the valve guides when
the valves are removed from the cylinder head. (11) Remove the valves, keeping them in order
for assembly to their original locations.
NOTE: To keep the valve assemblies in
order have a rack numbered from 1 to 8 and
instill the components in this rack, starting
from the front of the cylinder head.
(12) If the oil pressure relief valve in the cylinder
head is to be renewed, proceed as follows:
(a) Using a drift, remove the welch plug from
the distributor end of the cylinder head. (b) Remove the recessed screw from the thermo-
stat housing end of the cylinder head. (c) Using a long brass drift inserted in the oilway
through the tappet bores from the thermostat housing
end. remove the oil pressure relief valve from the
cylinder head. Discard the relief valve.
TO CLEAN AND INSPECT
(1) Clean the valves thoroughly and discard any
burnt, warped or cracked valves. (2) Have the valves refaced to the recommended
angle on a valve refacing machine. The valve stem tips
are specially hardened and should not be refaced.
Dismantled view of the valve and spring components.
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Engine 53
Method of checking cylinder head for distortion.
(3) Carefully clean the deposits from the inlet
and exhaust ports, the auxiliary passages, the valve
guides and the manifolds, taking care not to damage
any mating surfaces. (4) Clean the cylinder head mounting faces,
wash the cylinder head in solvent and dry with
compressed air. Blow through all the oil holes with
compressed air to ensure that they are not blocked. (5) Check the cylinder head for distortion diag-
onally and lengthwise using a straight edge and feeler
gauges. Refer to Specifications for the distortion and
machining limits. (6) Check the cylinder head face and combus-
tion chambers for cracks, burn marks and corrosion. (7) Check the valve stem to guide clearance. If
the clearance is in excess of the Specifications, the
valve guide must be reamed and the appropriate
oversize valve installed. (8) Inspect the valve seats for pitting or burning
and if necessary, recut the seats with a valve seat
cutter to the recommended angle. When the seats are
correctly finished, the seat widths should conform to
the Specifications. (9) Lap the valves to the valve seats with a fine
lapping compound. Apply a smear of Prussian blue to
the valves or their respective seats to ensure that true
and concentric seating has been gained.
(10) Install each valve in its respective port
and
check the valve stem height above the cylinder head.
Refer to the illustration. The extended height must
not exceed 18.4 mm. If the height exceeds the
Specifications, the valve or the cylinder head must be
renewed. Do not remove any material from the valve
stem tip.
(11) Check the valve spring tensions and compare
with the Specifications.
Check that the springs are not bent or distorted.
If a spring tester is not available, check the springs
by comparison with new springs. This can be done
using a surface plate and stra ight edge for checking the
free length and using a new spring and a used spring
loaded in a vice end on end, with a plate in between.
Measure from the plate to the vice jaw adjacent to
both the new and used springs. A used spring is
serviceable if it does not show collapse in excess of
five percent when subjected to this comparison test.
(12) Check the exhaust valve rotators for wear
and ensure that the rotators turn freely. (13) Clean the cylinder block face of all carbon
and rust deposits and ensure that all old gaskets are
removed. Do not allow the waste deposits to enter the
oil or water galleries. Clean all waste materials from the cylinder bores.
TO ASSEMBLE
Assembly is a reversal of the dismantling proce-
dure with attention to the following points:
(1) Lubricate all component wear surfaces with
engine oil before assembly to ensure adequate lubri-
cation when starting. (2) If the oil pressure relief valve was removed
from the cylinder head, proceed as follows:
(a) Using a brass tube inserted in the welch plug
hole at the distributor end of the cylinder head, tap
the relief valve into position. (b) Install the welch plug and the recessed screw
in their respective positions, after coating the plug and
the screw with Loctite 242 or equivalent.
(3) Install the inlet valve spring seats and
the
exhaust valve rotators over the valve guides before
installing the valve stem seals onto the valve guides.
(4) Install the valve stem seals, ensuring that
the
rib of the moulding on the inside of the seal is
correctly positioned in the groove of the valve guide
and that the spring clip retainer is correctly posi-
tioned.
NOTE: The valve stem seals can be posi-
tioned correctly and without damage using
an upturned valve spring retainer.
(5) Install the valves to their original location in
the cylinder head. Use care when installing the valves
to prevent damage to the seals.
(6) Install the valve springs, retainers and
collets.
Ensure that the valve retain ing collets are fully seated
Dimension A is the correct position to measure the
valve stem installed height. Dimension A = 18.4 mm.
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54 Engine
in the valve stem groove before releasing the spring
compressor. A sharp tap to the top of the valve stem
with a soft faced hammer will ensure that the collets
are correctly seated.
(7) Install the inlet and exhaust manifolds using
new gaskets and tighten the mounting nuts to the
specified torque as previously described. (8) Install a new sealing ring to the
thermostat
housing, install the housing to the cylinder head and
tighten the mounting bolts to the specified torque.
(9) Ensure that the lappet assemblies are filled
with clean engine oil and install the tappets in
their
respective bores in the cylinder head. (10) Install the thrust pads to the top of each
valve
assembly, ensuring that they are returned to their
original locations. (11) Coat the contact surfaces of the rocker arms
with molybdenum disulphide grease and install the
rocker arms to their origin al locations on the cylinder
head. (12) Install the cylinder head to the engine as
previously described.
8. ENGINE SUMP AND OIL PUMP PICKUP . PIPE
TO REMOVE
(1) Disconnect the negative battery terminal.
(2) Raise the front of the vehicle and support it
on chassis stands. Refer to the Wheels and Tires
section for the correct procedure.
(3) Remove the sump plug and drain the engine
oil into a container. Install and tighten the plug
after the oil has been drained.
(4)
Remove the engine pipe as described at the
end of this section.
(5) Remove the nuts and bolts retaining the
engine crossmember to the vehicle underbody and
withdraw the crossmember from the vehicle. On
automatic transaxle models, it will be necessary to
release the selector cable from the crossmember
bracket.
(6) Remove the sump retaining bolts and wash-
ers and if necessary firmly bump the sump with the
palm of the hand and remove it from the engine. (7) Remove the bolts retaining the oil pump
pickup pipe to the oil pump and disconnect the
pickup pipe from the support bracket. Remove the
pickup pipe and discard the O ring seal. (8) Remove the scraper and gasket from the
engine. (9) Clean the gasket material from the sump,
engine block and the scraper.
NOTE: If the scraper assembly is damaged
it should be renewed.
TO INSTAL
(1) Wash the inside of the sump to remove
carbon and sludge deposits. Check for any metal
deposits which may indicate an imminent component
failure. (2) Inspect the sump for dents and cracks.
Ensure that the gasket sea ling face is not distorted or
damaged. (3) Clean the pickup pipe screen with solvent
and a brush. (4) Using a new O ring seal, install the pickup
pipe. Coat the pipe retain ing bolts with Loctite 242
and tighten to the specified torque. (5) Apply a bead of KP510-00150 sealer or
equivalent to the oil pump to cylinder block mating
joint area. (6) Ensure that the sump gasket is correctly
located on the scraper and install the sump to
the
engine. Apply Loctite 242 to the threads of the sump
bolts and tighten the bolts to the specified torque.
(7) Install the front exhaust pipe using a
new
gasket and coat the threads of the flange nuts with an
anti-seize compound before tightening the nuts to the
specified torque. (8) Install the engine crossmember and
tighten
the nuts and bolts securely. If applicable, connect the
automatic transaxle selector cable to the crossmember
bracket. (9) Ensure that the sump drain plug is secure
and lower the vehicle to the ground. (10) Fill the engine with the specified amount and
grade of engine oil. Refer to the Lubrication and
Maintenance section if necessary. (11) Start and run the engine and check for oil
leaks.
View of the sump, oil pump pickup, gasket and scraper
removed from the engine.
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Engine 55
9. OIL PUMP
TO REMOVE AND DISMANTLE
(1) Disconnect the negative battery terminal.
(2) Disconnect the lower radiator hose and drain
the cooling system. (3) Raise the front of the vehicle and support it
on chassis stands. Refer to the Wheels and Tires
section if necessary. (4) Remove the right hand front wheel.
(5) Remove the fasteners securing the engine
splash guard to the right hand front inner mudguard
and remove the splash guard. (6) Remove the engine sump and oil pump
pickup pipe as previously described. Remove the oil
filter.
(7) Remove the camshaft timing belt as de-
scribed previously. (8) Disconnect the oil pressure sender electrical
connector. (9) Using a socket and bar, remove the bolt and
spacer retaining the crankshaft timing gear to the
crankshaft. Discard the bolt.
NOTE: It may be necessary to lock the
crankshaft when removing the crankshaft
timing gear retaining bolt. If necessary,
insert a piece of timber between the crank-
case and the crankshaft to prevent the
crankshaft turning.
(10) Remove the crankshaft timing gear from the
crankshaft. It may be necessary to lever the gear from
the crankshaft using two screwdrivers. Remove the
key and spacer from the crankshaft. (11) Remove the camshaft housing top cover.
(12) Using an open ended spanner, hold the
camshaft between the inlet and exhaust lobes of
number four cylinder and remove the camshaft timing
gear retaining bolt and the camshaft timing gear.
(13) Remove the bolts securing the water pump
to the cylinder block and remove the water pump. If
necessary- refer to the Cooling and Heating Systems
section. (14) Remove the camshaft drive belt inner cover
retaining bolts and remove the inner cover. (15) Remove the bolts securing the oil pump to
Dismantled view of the oil pump assembly.
the cylinder block and remove the oil pump from the
engine. Discard the gasket.
(16) Remove the screws retaining the oil pump
cover plate and lift the cover plate from the rear of the
oil pump. (17) Lift the inner and outer rotors from the oil
pump housing. Note that the outer rotor may be
stamped with a mark which must face the cover plate
on assembly. (18) Unscrew the oil pressure relief valve plug
and remove the relief spring and plunger from the oil
pump housing. Discard the sealing washer from the
relief valve plug. (19) If necessary, remove the oil pressure gauge
sender unit.
(20) Remove the crankshaft oil seal from the
pump housing.
TO CHECK AND INSPECT
(1) Wash all the pump components thoroughly
in cleaning solvent and allow to dry.
(2) Inspect the inner and outer rotors and the
cover plate for scoring or wear. Renew the rotors
and/or the cover plate if these faults are evident. (3) Temporarily install the rotors into the oil
pump housing. Check the b acklash between the teeth
of the inner and outer rotors at the point where the
rotor teeth are most closely meshed. If the clearance at
this point exceeds the Specif ications, check the rotors
and housing for wear and renew as necessary. (4) Check the rotor end float by placing a
straight edge across the oil pump housing and measure
the clearance between the straight edge and the rotors
View of the oil pump and associated components.
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56 Engine
Checking the oil pump rotor end float.
with a feeler gauge. Renew the oil pump if this
clearance exceeds the Specifications.
(5) Check the cover plate for wear and scoring
and renew as necessary. (6) Check the relief valve plunger and spring for
wear or damage. Renew any faulty components as
necessary.
TO ASSEMBLE AND INSTAL
Assembly is a reversal of the dismantling proce-
dure with attention to the following points:
(1) Liberally lubricate all components with clean
engine oil before assembly. (2) Install the relief valve plunger and spring into
the pump housing and install the relief valve
plug
using a new sealing washer. Tighten the plug securely. (3) Install the outer rotor into the pump housing with the F mark on the rotor facing towards the cover
plate, if applicable. Install the inner rotor ensuring that
it is correctly meshed with the teeth of the outer rotor.
(4)
Install the cover plate to the oil pump housing
and tighten the retaining screws to the specified
torque. (5) Install a new oil seal to the front of the oil
pump housing. Ensure that the lip of the oil seal faces
the inside of the oil pump housing. (6) If necessary, install the oil pressure gauge
sender unit.
(7) Turn the inner rotor in the oil pump housing.
Ensure that the oil pump rotates freely. (8) Ensure that the mating surfaces of the oil
pump and cylinder block are thoroughly clean. Coat
the oil pump gasket with an oil resistant sealer and
install the oil pump and gasket to the cylinder block. It
may be necessary to turn the oil pump slightly to align
the inner rotor and crankshaft. Tighten the retaining
bolts to the specified torque.
NOTE: Ensure that the oil seal installed to
the oil pump is not damaged when the oil
pump is positioned on the crankshaft.
(9) Install the camshaft drive belt inner cover.
(10) Install the water pump using a new O ring.
Coat the water pump and the engine block mating
surfaces with Dow Corning silicone grease or equiva-
lent. Do not fully tighten the water pump retaining
bolls at this stage. (11) Install the camshaft timing gear and tighten
the retaining bolt to the specified torque.
(12) Install the crankshaft timing gear spacer, key
and timing gear to the crankshaft. (13) Using a new crankshaft timing gear retaining
bolt, install the spacer and tighten the retaining bolt to
the specified torque. (14) Ensure that the oil pump pickup pipe and
screen are clean and free of foreign material. Install a
new O ring to the pipe and position the pickup pipe
and screen in position on the oil pump. Coat the
threads of the mounting bolts with Loctite 242 and
torque the bolts to the specified torque. (15) Fill a new oil filter with the correct grade of
engine oil and install the oil filter. (16) Install the sump as previously described.
(17) Install and adjust the camshaft drive belt as
described under the Camshaft Drive Belt heading. (18) Fill the engine with the correct grade and
quantity of oil. Refer to the Lubrication and Mainte-
nance section.
(19) Fill the cooling system as described in the
Cooling and Heating Systems section. (20) Start and run the engine and check for oil
and coolant leaks. (21) Install the engine splash guard to the
inner
right hand mudguard. (22) Install the right hand wheel and tighten the
wheel nuts as much as possible.
Checking the oil pump inner to outer rotor teeth
backlash.
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Engine 57
(23) Lower the vehicle to the ground and securely
tighten the wheel nuts.
10. PISTONS, CONNECTING RODS AND
CYLINDER BORES
Special Equipment Required:
To Inspect — Micrometer, cylinder measuring
gauge
To Remove Ridge from Bores — Ridge removal tool
To Deglaze Cylinder Bores — Cylinder surfacing
hone
To Install — Piston ring compressor
TO REMOVE
(1) Remove the engine sump and oil pump
pickup pipe as previously described. (2) Remove the cylinder head as previously
described. (3) Mark the relationship of the pistons to their
respective cylinders and the bearing caps to their
respective connecting rods by letter stamps or centre
punch marks. (4) Measure each connecting rod for side clear-
ance on the crankpin. Refer to the illustration. If the
clearance exceeds the Speci fications a new connecting
rod will have to be installed on assembly. (5) With number one cylinder on the bottom of
its stroke, remove the bear ing cap bolts and the
bearing cap. Wipe the bearing shell and the exposed part of the
journal with a piece of clean lint free cloth, insert a
piece of Plastigage across the journal, install the
bearing cap and tighten the bolts to the specified
torque.
Remove the bolts and cap and measure (with the
scale on the packet) the spread width of the Plastigage
to determine the bearing clearance.
Compare the measurement to the Specifications
and if the bearing clearance exceeds the limit, install a
new bearing on assembly.
Repeat the procedure on the remaining cylinders
and note each individual bearing clearance for assem-
bly purposes.
NOTE: Do not rotate the engine while the
Plastigage is in position or false readings
will result.
Dismantled view of the piston and connecting rod
components.
(6) Remove each bearing cap in turn, keeping
them in order, and using a wooden hammer shaft,
push each piston assembly from the cylinder block
and install its respective bearing cap.
NOTE: Before removing the pistons, remove
the ridge from the top of the cylinder bore
using a ridge removal tool.
(7) Remove the piston rings over the top of the
piston and discard the piston rings.
Checking the connecting rod side clearance using feeler
gauges.
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58 Engine
TO INSPECT PISTONS AND CONNECTING
RODS
(1) Remove all carbon deposits from the bottom
of the ring grooves with a ring groove cleaning tool or
a broken ring. Use caution to avoid scoring the
bottom and sides of the ring groove.
NOTE; An ideal method of removing carbon
deposits from pistons is to immerse the
piston in a tank of chemical cleaner. After
soaking, the carbon can be readily hosed off
with water. This method minimizes the
chance of damage through scraping, particu-
larly with aluminum alloy components.
(2) Inspect the pistons for sc uff marks, scoring or
burning. (3) Inspect the ring grooves of the pistons for
excessive wear. Using a new piston ring, check the
clearances between the side of the ring and the ring
lands of the piston with feeler gauges. Compare the
side clearance with the Specifications. (4) Inspect each pair of bearing shells for wear
especially on an outer edge. If one or more pairs of
bearing shells are worn on the outer edge it is possible
that the connecting rod is bent. (5) Before renewing a piston or connecting rod,
inspect the cylinder block to see if it requires reboring
or honing.
If the cylinder block requires reboring, new over-
size pistons will have to be installed.
(6) If a piston or connecting rod is to be
renewed, a special tool wi ll be required to press the
gudgeon pin from the connecting rod. To install the
piston and gudgeon pin to the connecting rod, the
gudgeon pin boss must be accurately heated to 280
degrees C before the gudgeon pin can be inserted in
the little end of the connecting rod.
Replacement connecting rods are supplied only at
their highest production weight and must be matched
to the weight of the remaining connecting rods by
filing the big end boss. For these reasons it is
recommended that the work be entrusted to a repu-
table engine reconditioner w ho will have the special-
ised equipment and knowledge to carry out this work.
TO INSPECT CYLINDER BLOCK AND BORES
With the pistons removed as previously de-
scribed, carry out the following checks and measuring
procedures:
(1) Check the cylinder bores for cracks, scores or
scuffs.
Check for cylinder bore wear. Difference between A
and B measurement at top of piston travel is out of
round dimension. Difference between A at top and at
bottom of piston travel is cylinder taper.
(2) Using an accurate cylinder gauge, measure
each cylinder bore for wear. Take the measurements,
at the upper and lower sections of the bore in two
directions — along and across the cylinder block.
Refer to the illustration.
(3) If the wear in any cylinder exceeds the
specified limit, rebore and hone all the cylinders to the
nearest oversize for pistons and rings. (4) With a straight edge and feeler gauge, check
the top face of the cylinder block for distortion, using
the same procedure described for the cylinder head.
STRAIGHT EDGE
Measuring the piston ring side clearance.
Checking the cylinder block face for distortion.
Page 59 of 238
Engine 59
(5) If the engine is completely dismantled, thor-
oughly clean the cylinder block with solvent and
compressed air paying particular attention to the
oilways. Inspect the block for cracks and damage.
TO CHECK PISTON CLEARANCE
(1) Using an accurate cylinder measuring gauge,
measure and note the diameter of each bore as
previously described. (2) Measure each piston skirt using a microme-
ter as follows:
(a) On 1.6 liter models, measure each piston
skirt at a point 9 mm above the bottom skirt edge and
at right angles to the gudgeon pin axis. (b) On 1.8 liter models, measure each piston
skirt at a point 6 mm above the bottom skirt edge and
at right angles to the gudgeon pin axis.
(3) The difference between the bore and the
piston measurement is the piston clearance. If the
clearance exceeds the Specifications, renew the pistons
and rebore all the cylinders.
(4) Cylinders that have had new pistons installed
or that have been rebored should have the piston
clearance checked again.
and not engine or transmission oil, mineral spirits or
kerosene.
(2) Honing should be carried out by moving the
hone up and down fast enough to obtain a cross hatch
pattern. When hone marks intersect at 60 degrees, the
pattern is most satisfactory for correct seating of rings.
(3) After honing it is necessary that the block be
cleaned again to remove all traces of abrasives.
NOTE: When deglazing, the cylinder should
be honed only sufficiently to eliminate the
glazed condition. Excessive honing will in-
crease the bore size and alter the piston
clearance.
(4) When honing is complete, ensure that the
cylinder bore, crankcase area and oilways are thor-
oughly cleaned. (5) After the cylinder block has been cleaned and
dried, wipe the bores with a lint free cloth and smear
them with engine oil to prevent rusting.
NOTE: All abrasives must be removed from
the engine components after honing. A so-
lution of soap and water should be used with
a brush and the components thoroughly
dried. A bore can be considered clean when
it can be wiped clean with a white cloth and
the cloth remains clean. Oil the bores after
cleaning to prevent rusting.
TO FIT NEW PISTON RINGS AND INSTAL
PISTONS
Once the correct piston and the bore relationship
has been determined and the pistons cleaned or
renewed as necessary, proceed as follows:
(1) Place a ring into number one cylinder bore
and using an inverted piston push the ring down 50
mm into the cylinder bore. (2) Withdraw the piston and measure the gap in
the ring with feeler gauges. Adjust the end gap of the
ring by filing as necessary. See the Specifications for
the ring end gap.
Measuring the piston diameter using a micrometer. On
1.6 liter models, dimension A = 9 mm. On 1.8 liter
models, dimension A - 6 mm.
TO INSPECT AND DEGLAZE CYLINDER
BORES
Cylinder bores that are fit for further service with
the original pistons, but require re-ringing, should be
deglazed with a hone. Before honing the cylinder
bores with crankshaft insta lled, place plenty of clean
rag over the crankshaft to keep the abrasive materials
from entering the crankcase area.
(1) Deglaze the cylinder walls using a cylinder
surfacing hone equipped with suitable stones. Inspect
the cylinder walls after each 20 strokes. Use honing oil
Checking the piston ring end gap.
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60 Engine
NOTE: Should the ring end gap be greater
than the specified gap, another ring set
should be obtained and the ring end gaps
checked and compared with the Specifica-
tions.
(3) Treat each ring and cylinder bore individu-
ally and ensure that the rings are assembled to the
respective piston for the cylinder bore in which they
were installed to check the end gap.
(4) Assemble each oil control ring to its respec-
tive piston bottom groove as follows:
(a) Install the oil ring expander to the
piston
groove, ensuring that the ends of the expander are
bulled together and not overlapped. (b) Position one end of the lower side rail in the
groove and peel the ring over the piston and into the
groove. (c) Similarly install the upper side rail.
(5) Install the lower compression ring into
the
lower piston groove.
NOTE: The compression rings should be
installed with the manufacturers mark fac-
ing the top of the piston. To minimize the
possibility of ring breakage the rings can be
immersed in hot water prior to installation.
(6) Install the upper compression ring into
the
upper piston groove.
(7) Space the compression ring gaps 120 degrees
apart, and ensure that the o il ring gaps and the join in
the oil ring expander are not aligned. (8) With the rings correctly installed and
gapped, remove the bearing cap from the connecting
rod. (9) Liberally lubricate the piston assembly and
install the piston ring compressor to number one
piston.
NOTE: When installing the pistons to the
cylinder ensure that the front marking on
the piston is towards the front of the engine.
(10) Turn the crankshaft until number one crank-
pin is at the bottom of its stroke. (11) Install number one piston and connecting
rod
assembly into its bore. Push the assembly down the
bore until the connecting rod can be aligned with
number one crankpin.
NOTE: The bearing shells should be lubri-
cated with engine oil before installation.
(12) Install the connecting rod cap and tighten
the
retaining bolts to the specified torque.
NOTE: If new bearing shells were installed,
check the bearing clearance with Plastigage
as previously described.
(13) With the bearing clearance as specified, in-
stal the remaining pistons in the same manner.
(14) Ensure that the crankshaft turns without
binding.
(15) With all connecting rod bolts tightened to
the specified torque, install the associated
components
by referring to the relevant headings in this section.
11. CRANKSHAFT AND MAIN BEARINGS
Special Equipment Required:
To Inspect — Micrometer, Vee blocks, dial gauge
TO REMOVE
(1) With the engine assembly removed from the
vehicle and the transaxle separated from the engine,
refer to the appropriate headings or sections and
remove the following components: sump, oil pump
pickup pipe, oil pump, and flywheel or drive plate. (2) Remove the crankshaft rear oil seal from the
Using a ring compressor to install the piston.
Checking the crankshaft end float using feeler gauges.