Apply sealant to the front side of the front rotor housing

Install the O-ring (right arrow), outer sealing rubber (left arrow) and inner sealing rubber

Install the seal protector behind the inner sealing rubber

Mount the front housing on a workstand so that the top of the housing is up. Install the thrust plate so that the chamfered edge faces the front of the housing. Torque the thrust plate bolts to 12-17 ft. lbs. (16-23 Nm).

Lubricate the internal gear of the rotor with engine oil.

Hold the apex seals with a rubber band around the rotor's perimeter to keep the seals attached. Place the rotor on the front housing, being careful not to drop the seals. Turn the front housing so that the sliding surface faces upward.

Mesh the internal and stationary gears so that one of the rotor apexes is at any one of the four places shown, then remove the rubber band which is holding the apex seals in position.

Lubricate the front rotor journal of the eccentric shaft and the eccentric shaft main journal with engine oil.

Insert the eccentric shaft. Be careful that you do not damage the rotor bearing and main bearing.

Apply sealing agent to the front side of the front rotor housing.

Apply a light coat of petroleum jelly (not grease) onto new O-rings and rubber seals, then install the O-rings and seals on the front side of the rotor housing. If the engine is being overhauled, install the seal protector behind the inner sealing rubber to improve durability.

The inner rubber seal is of the square type. The wider white line of the rubber seal should face the combustion chamber and the seam of the rubber seal should be positioned as illustrated. Do not stretch the rubber seal.

Fitting an assist piece on the apex seal

Install the side piece as shown under "O." (The spring must butt against the apex seal lip.)

Rotary engine tension bolt tightening sequence

Invert the front rotor housing, being careful not to let the rubber seals and O-rings fall from their grooves, and mount it on the front housing.

Lubricate the tubular dowels with engine oil, then insert them through the front rotor housing holes and into the front housing.

Insert each apex seal spring so that both ends of the spring may support the back side of the seal.

Install the corner seal springs and corner seals into their respective grooves.

Install the side seal springs and side seals into their respective grooves.

Fit an assist piece between the spring and seal, then install each side piece in its original position. Be sure that the spring seats properly on the side piece, as shown.

Confirm the smooth movement of each seal by pressing its head.

Apply sealer to the rear side of the front rotor housing.

Install new O-rings, rubber seals and seal protector on the rear side of the front rotor housing, in the same manner as on the front side.

Lubricate the side pieces with engine oil. Make sure that the front rotor housing is free of foreign matter and lubricate the sliding surface of the front housing with engine oil.

Turn the front housing assembly with the rotor, so that the top of the housing is up. Pull the eccentric shaft about 1 in. (25mm).

Position the eccentric portion of the eccentric shaft diagonally, to the upper right.

Install the intermediate housing over the eccentric shaft and onto the front rotor housing. Turn the engine so that the rear of the engine is up.

Install the rear rotor and rear rotor housing, following the same steps as for the front rotor and front rotor housing.

Lubricate the stationary gear and main bearing.

Install the rear housing onto the rear rotor housing. Make sure the side pieces of the front and rear apex seals are not pinched between the rotor and side housings.

If necessary, turn the rear rotor slightly to mesh the rear housing stationary gear with the rear rotor internal gear.

Install a new washer on each tension bolt, and lubricate each bolt with engine oil.

Install the tension bolts, then tighten them to specification using several stages of the proper sequence. Be sure the bolts are installed in their original positions with new seal washers. Longer bolts are used in later engines and are not interchangeable.

On 1984-85 carbureted engines, bolt number 11 does not apply. For those engines, delete bolt number 11 from the tension bolt torque sequence.

After tightening the bolts, turn the eccentric shaft to be sure that the shaft and rotors turn smoothly and easily.

Lubricate the oil seal in the rear housing.

On vehicles equipped with a manual transmission, install the flywheel on the rear of the eccentric shaft so that the keyway of the flywheel fits the key on the shaft.

Apply sealer to both sides of the flywheel lockwasher and install the lockwasher.

Install the flywheel locknut. Hold the flywheel securely and tighten the nut to 350 ft. lbs. (475 Nm).

On vehicles with an automatic transmission, install the key, counterweight, lockwasher and nut. Tighten the nut to 350 ft. lbs. (475 Nm). Install the driveplate on the counterweight and tighten the attaching nuts.

Turn the engine so that the front faces up.

Install the thrust plate with the tapered face down, and install the needle bearing on the eccentric shaft. Lubricate with engine oil.

Install the bearing housing on the front housing. Tighten the bolts and bend up the lockwasher tabs. The spacer should be installed so that the center of the needle bearing comes to the center of the eccentric shaft, and the spacer should be seated on the thrust plate.

Install the needle bearing on the shaft and lubricate it with engine oil.

Install the balancer and thrust washer on the eccentric shaft.

Install the oil pump drive chain over both of the sprockets. Install the sprocket and chain assembly over the eccentric shaft and oil pump shaft simultaneously. Install the key on the eccentric shaft. Be sure that both of the sprockets are engaged with the chain before installing them over the shafts.

Install the distributor drive gear onto the eccentric shaft with the Fmark on the gear facing the front of the engine. Slide the spacer and oil slinger onto the eccentric shaft.

Align the keyway and install the eccentric shaft pulley. Tighten the pulley bolt to 72-87 ft. lbs. (98-118 Nm) on 1979-85 engines and 80-98 ft. lbs. (108-133 Nm) on 1986-89 engines.

Turn the engine until the top of the engine faces up.

Check the eccentric shaft end-play in the following manner:

Attach a dial indicator to the flywheel. Move the flywheel forward and backward.

Note the reading on the dial indicator, it should be 0.0016-0.0028 in. (0.04-0.07mm).

If the end-play is not within specification, adjust it by replacing the front spacer. Spacers come in four sizes, ranging from 0.3150-0.3181 in. (8.00-8.08mm). If necessary, a spacer can be ground on a surface plate with emery paper.

Check the end-play again and, if it is now within specification, proceed with the next Step.

Remove the pulley from the front of the eccentric shaft. Tighten the oil pump drive sprocket nut and bend the locktabs on the lockwasher.

Fit a new O-ring over the front cover oil passage.

Install the chain tensioner, if equipped, and tighten its securing bolts.

Position the front cover gasket and the front cover on the front housing, then secure the front cover with its attachment bolts.

Install the eccentric shaft pulley again. Tighten its bolt to the required torque value.

Turn the engine so that the bottom faces up.

Cut off the excess gasket on the front cover along the mounting surface of the oil pan.

Install the oil strainer gasket and strainer on the front housing, then tighten the attaching bolts.

Apply sealer to the joint surfaces of each housing.

Install the oil pan.

Turn the engine so that the top is up, then complete assembly of the external components.

Assembly of External Components

CARBURETED ENGINES

Install the water pump.

Attach two O-rings to the oil filter body, then install the oil filter.

Rotate the eccentric shaft until the yellow mark (leading side mark) aligns with the pointer on the front cover.

Align the marks on the drive gear and housing, then install the distributor so that the lockbolt is in the center of the slot.

Rotate the distributor until the leading points start to separate (1979 only) or the air gap is correct (1980-1985), then tighten the distributor locknut. (For more details, please refer to Section 2.)

Install the gaskets and thermal reactor/exhaust manifold.

Install the hot air duct.

Install the carburetor (if applicable) and intake manifold assembly.

Connect the oil tubes, vacuum tube and metering oil pump connecting rod to the carburetor.

Install the decel valve, then connect the vacuum lines, air hoses and wires.

Install the alternator bracket, alternator and retaining bolt, then check the clearance. If the clearance is more than 0.006 in. (0.15mm), adjust the clearance using a shim. Shims are available in three sizes: 0.0059 in. (0.15mm), 0.012 in. (0.30mm), and 0.02 in. (0.50mm).

Install and properly tension the alternator and accessory drive belts.

Remove the engine from the stand and install it in the vehicle.

FUEL INJECTED ENGINES

Install the water pump and tighten the nuts in a crisscross sequence. Tighten to 13-20 ft. lbs. (18-27 Nm). Be sure to use shims on the side housing contact surfaces.

If shims are not used, the coolant will leak.

Apply engine oil to the new O-ring, then install the metering oil pump to the front housing.

Place the exhaust manifold gasket in position and install the exhaust manifold. Tighten to 23-34 ft. lbs. (31-46 Nm).

Install the hot air duct and absorber plate.

Install the intake manifold auxiliary ports. Installation should be made so that the bigger sides of the auxiliary port valve shaft align with the matching mark on the gasket, as illustrated.

Install the O-rings and the intake manifold and gasket.

Connect the metering oil pump pipes, and tighten to 14-19 ft. lbs. (19-26 Nm).

Install the fuel injection nozzles.

Install the delivery pipe assembly, the throttle/dynamic chamber, and the emission device assembly as one piece. Tighten the delivery pipe body to 14-19 ft. lbs. (19-26 Nm), and the emission device assembly to 14-19 ft. lbs. (19-26 Nm).

Install the vacuum sensing tube, the air pump, and the engine hanger bracket.

Align the leading timing mark (painted yellow) on the eccentric shaft pulley with the indicator pin on the front cover.

On models equipped with a distributor, align the tally marks on the distributor housing and driven gear. Install the distributor and locknut. Turn the distributor housing until the projection of the signal rotor aligns with the core of the leading side pick-up coil. Tighten the locknut. Install the distributor rotor and cap.

On models equipped with a crank angle sensor, apply engine oil to a new O-ring and install it on the crank angle sensor. Apply engine oil to the drive gear, then match the mating mark and install the crank angle sensor on the front housing.

Attach two O-rings to the oil filter body, then install the oil filter.

Install and properly tension the alternator and accessory drive belts.

Remove the engine from the stand and install it in the vehicle.

 

 

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