Engine dismantling, examination, renovation and reassembly - general information
1.8 litre (R2A type)
1 It is best to mount the engine on a dismantling stand, but if this is not available, stand the engine on a strong bench at a comfortable working height. Failing this, it will have to stripped down on the floor.
2 Cleanliness is most important, and if the engine is dirty, it should be cleaned with paraffin while keeping it in an upright position.
3 Avoid working with the engine directly on a concrete floor, as grit presents a real source of trouble.
4 As parts are removed, clean them in a paraffin bath. However, do not immerse parts with internal oilways in paraffin as it is difficult to remove, usually requiring a high pressure hose. Clean oilways with nylon pipe cleaners.
5 It is advisable to have suitable containers available to hold small items according to their use, as this will help when reassembling the engine and also prevent possible losses.
6 Always obtain a complete set of new gaskets for use during engine reassembly, but retain the old gaskets with a view to using them as a pattern to make a replacement if a new one is not available.
7 Where possible, refit securing nuts, bolts and washers to their locations after removing the relevant components. This will help to protect the threads and will also prevent possible losses.
8 Retain unserviceable components in order to compare them with the new components supplied.
9 A suitable Torx socket will be required to remove the oil pump cover securing screws.
10 Before dismantling the main engine
components, the following externally mounted
ancillary components can be removed:
Inlet manifold and carburettor
Fuel pump and operating pushrod Alternator
Oil pressure warning lamp switch (see illustration)
17.10 Removing the oil pressure warning lamp switch - 1.8 litre (R2A)
Engine mounting brackets Clutch
Alternator mounting bracket Crankshaft speed/position sensor Engine lifting brackets
Examination and renovation 11 Refer to Section 18 in Chapter 2, Part A.
12 To ensure maximum life with minimum trouble from a rebuilt engine, not only must everything be correctly assembled, but it must also be spotlessly clean. All oilways must be clear, and locking washers and spring washers must be fitted where indicated. Oil all bearings and other working surfaces thoroughly with engine oil during assembly.
13 Before assembly begins, renew any bolts or studs with damaged threads.
14 Gather together a torque wrench, oil can, clean rag, and a set of engine gaskets and oil seals, together with a new oil filter.
15 If they have been removed, new cylinder head bolts, big-end bolts/nuts and new flywheel bolts will be required.
16 After reassembling the main engine components, refer to paragraph 10 and refit the ancillary components listed. Delicate items such as the alternator may be left until after the engine has been refitted.
1.6 and 1.8 litre (R6A type)
17 Refer to paragraphs 1 to 9 inclusive.
18 Before dismantling the main engine components, the following ancillary components can be removed: Inlet manifold and CFI unit.
Exhaust manifold .
Spark plugs and HT leads.
Ignition coil and mounting bracket.
Oil pressure warning lamp switch.
Dipstick and tube.
Engine mounting brackets.
Alternator mounting bracket.
Crankshaft speed/position sensor.
Engine lifting brackets.
Crankcase ventilation hose.
Examination and renovation 19 Refer to Section 18 in Chapter 2, Part A.
20 Refer to paragraphs 12 to 16 but note that new rocker arm nuts will be required, if they have been removed.
Cylinder head - removal and refitting (engine removed)
Note: Up to early 1984, splined type cylinder head bolts were used, and from early 1984, size T55 Torx bolts were used. Torx type bolts must always be renewed after slackening. The two types of bo ...
Steering intermediate shaft and flexible coupling - removal and refitting
Removal 1 Apply the handbrake, jack up the front of the vehicle and support on axle stands. 2 Working in the engine compartment, unscrew the bolt securing the intermediate shaft to the inner colu ...
Spark plugs and HT leads - removal, inspection and refitting
Note: The correct functioning of the spark plugs is vital for the correct running and efficiency of the engine. It is essential that the plugs fitted are appropriate for the engine, and the suitabl ...