External Components
GENERATOR AND DRIVE BELT
Removal
Follow removal steps outlined in illustration.
Removal Service Point
[A] Crankshaft Bolt Loosening
(1) Using the special tool, hold the drive plate or flywheel.
(2) Remove the crankshaft bolt.
Installation Service Point
]A[ Crankshaft Bolt Tightening
(1) Using the special tool, hold the drive plate or flywheel.
(2) Install the crankshaft bolt.
INTAKE MANIFOLD PLENUM AND THROTTLE BODY
Removal
Follow removal steps outlined in illustration.
Installation
Installation in reverse order as removal.
IGNITION SYSTEM
Removal
Follow removal steps outlined in illustration.
Installation
Installation in reverse order as removal.
Installation Service Point
]A[ Distributor Installation
(1) Turn the crankshaft so that the No. 1 cylinder is at compression top dead center.
(2) Align the distributor housing and gear mating marks
(3) With the stud located in the center of the adjusting slot at the distributor, install the distributor.
TIMING BELT
Removal
Follow removal steps outlined in illustration.
Removal Service Points
[A] Timing Belt Removal
(1) Mark the belt running direction for reference in reinstallation.
NOTE:
(1) Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be kept free from oil and water. Do not immerse parts in cleaning solvent.
(2) If there is oil or water on any part, check the front case oil seal, camshaft oil seal and water pump for leaks.
[B] Camshaft Sprocket Bolt Removal
Installation
Installation in reverse order as removal.
Installation Service Points
]A[ Camshaft Sprocket Bolt Tightening
]D[ Timing Belt Tensioner Installation
(1) Insert a screwdriver into the hole of the timing belt tensioner arm, move it all the way in the direction of the arrow, and tighten the tensioner lock bolt to temporarily hold this position.
]F[ Timing Belt Installation
(1) Align the timing marks of the camshaft sprockets and the crankshaft sprocket.
(2) Install the timing belt on the crankshaft sprocket first and while keeping the belt tight on the tension side, install the belt on the left camshaft sprocket.
(3) Then, install on the water pump pulley and on the right camshaft sprocket and finally on the timing belt tensioner.
(4) Install the flange onto the front end of the crankshaft.
(5) Install the special tool onto the crankshaft.
(6) Loosen the tensioner lock bolt one or two turns and allow the spring to tension the timing belt.
(7) Turn the crankshaft two full turns clockwise. Turn smoothly and in clockwise direction only.
(8) Again line up the timing marks on the sprockets and tighten the tensioner lock bolt to the specified torque.
]H[ Engine Support Bracket Installation
(1) Tighten the engine support bracket bolts in the order shown in the illustration.
NOTE: The bolt used at the location shown in the illustration is a reamer bolt (head mark "R").
Inspection
Timing Belt
Replace belt if any of the following conditions exist.
(1) Hardening of back rubber-back side is glossy without resilience and leaves no indent when pressed with fingernail.
(2) Cracks on rubber back.
(3) Cracks or peeling of canvas.
(4) Cracks on tooth bottom.
(5) Cracks on belt.
(6) Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife.
(7) Abnormal wear on teeth
(8) Tooth missing and canvas fiber exposed.
Tensioner
(1) Turn the pulley. If it rotates unsmoothly, develops noise or excessive play, replace the timing belt tensioner.
INTAKE MANIFOLD AND FUEL PARTS
Removal
Follow removal steps outlined in illustration.
Installation
Installation in reverse order as removal.
]B[ Sealant Application To Engine Coolant Temperature Sensor
Specified sealant:
3M Nut Locking No. 4171 or equivalent
]C[ Sealant Application To Engine Coolant Temperature Gauge Unit
Specified sealant:
3M ATD Part No. 8660 or equivalent
]D[ Intake Manifold Installation
(1) Tighten the nuts on the right bank to 5 - 8 Nm (3.7 - 5.9 ft. lbs.).
(2) Tighten the nuts on the left bank to the specified torque. Then tighten the nuts on right bank to the specified torque.
(3) Tighten the nuts on the left bank and those on the right bank again in that order.
]E[ Injector Installation
(1) Before installing the injector, the rubber O-ring must be lubricated with a drop of new engine oil for easy installation.
CAUTION: Use care not to let engine oil enter the fuel rail.
(2) Insert the injector top end into the fuel rail. Be careful not to damage O-ring during installation.
]F[ Fuel Pressure Regulator Installation
(1) Before installing the pressure regulator, the O-ring must be lubricated with a drop of new engine oil for easy installation.
CAUTION: Use care not to let the engine oil enter the fuel rail.
EXHAUST MANIFOLD
Removal
Follow removal steps outlined in illustration.
Installation
Installation in reverse order as removal.
]C[ O-ring And Water Pipe Installation.
(1) Wet the O-ring (with water) to ease assembly.
CAUTION: Keep the O-ring free of oil or grease.
ENGINE BRACKETS
Removal
Follow removal steps outlined in illustration.
Installation
Installation in reverse order as removal.