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.
10. Remove water pump and heater hose assemblies.
11. On manual transmission models, remove clutch cover, disc and flywheel, Fig. 2.
12. On automatic transmission models, remove drive and back plate.

Fig. 3 Oil pan, oil filter duct & fittings. 4-97/1600cc & 1984 4-109/1800cc engines:

13. On all models, invert engine and remove oil pan, oil pan gasket, and transmission cover, Fig. 3.
14. Remove oil level gauge bracket and pitching stopper bracket.
15. Remove flywheel housing.

Fig. 4 Valve train components. 4-97/1600cc & 1984 4-109/1800cc engines:

16. Remove the valve rocker covers and gaskets, Fig. 4.
17. Remove valve rocker locknuts and adjusting screws.

Fig. 5 Valve rocker assembly. 4-97/1600cc & 1984 4-109/1800cc engines:

18. Remove rocker assemblies and pushrods, Fig. 5. If pushrods are to be reused, keep them in order. They should be reinstalled in their original positions.

Cylinder Head Removal:

19. Remove cylinder head nuts in sequence shown in Fig. 6.

Fig. 7 Cylinder head assembly. 4-97/1600cc & 1984 4-109/1800cc engines:

20. Remove cylinder heads and gaskets, Fig. 7.
21. Remove oil strainer retaining bolt and nut. Never attempt to remove strainer unless necessary.
22. To remove piston pin circlip on rear side of No. 3 and 4 piston proceed as follows:
a. Install crankshaft pulley bolt. Using a suitable wrench rotate crankshaft.
b. Rotate piston to BDC.
c. Insert long needle nose pliers through the rear service hole to reach the pin circlip.
23. Remove No. 3 and 4 piston pins using piston pin remover 399094300 through rear service holes.
24. Remove crankcase plugs from case using an Allen wrench 14 mm wide across the flats.
25. Remove No. 1 and 2 piston pin circlips and pins in the same manner as previously described. Use the front service holes for these cylinders.
26. Straighten camshaft retaining bolt lockwashers and remove bolts.
27. Install valve lifter clips 899804100 to prevent lifters from dropping. On models equipped with hydraulic lifters, tilt crankcase and remove lifters.
28. Pull camshaft rearward so that it does not interfere with crankcase removal.

Fig. 8 Crankcase assembly. 4-97/1600cc & 1984 4-109/1800cc engines:

29. Separate the crankcase halves by removing the retaining nuts and bolts with cylinder No. 1 and 3 facing upward, Fig. 8.
30. Remove front oil seal, O-ring, and back-up ring.
31. Remove crankshaft, connecting rods, distributor gear and crankshaft gear as a unit.
32. Remove camshaft and camshaft gear and plate as an assembly.
33. Remove valve lifters and keep them in order. They should be reinstalled in their original positions.
34. Remove pistons from the crankcase. Keep the piston pins together with their respective pistons and make marks on the pistons in order to return them to their original positions.
35. Remove crankshaft bearings. If the bearings are to be used again, mark them in order to return them to their original positions.
36. Remove oil pressure switch or plug and remove engine stands from the case halves.