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.
2. Remove the crankshaft bolt.
Installation
Installation in reverse order as removal.
Installation Service Point
]A[ Crankshaft Bolt Tightening.
1. Using the special tool, hold the drive plate or flywheel.
2. Install the crankshaft bolt.
]B[ Drive Belt Tension Adjustment.
1. Use a belt tension gauge to check belt tension, or check deflection by applying 98 Nm.m. (22 lbs) to the shown point.
Standard value
Standard value
IGNITION SYSTEM
Removal
Follow removal steps outlined in illustration.
Installation
Installation in reverse order as removal.
Installation Service Point
]A[ Distributor Installation.
1. Align the mark on the distributor housing with that of the coupling and install the distributor.
2. Once the engine has been started verify that the ignition timing is correct.
TIMING BELT
Removal
Pre-removal Operation:
- Crankshaft pulley.
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. 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 Loosening.
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 side of 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.
Auto-Tensioner
1. Check for oil leaks. If oil leaks are evident, replace the auto-tensioner.
2. Check the rod end for wear or damage and replace the auto-tensioner if necessary.
3. Measure the rod projection length. If the reading is outside the Standard value, replace the auto-tensioner.
Standard value: 11.7 - 12.3 mm (0.461 - 0.484 inch)
4. Press the rod with a force of 98 to 196 Nm. (22 to 44 lbs.) and measure the movement of rod.
If the measured value is out of the standard value, replace the auto-tensioner.
Standard value: 1 mm (0.0393 inch) or less.
Installation
Installation in reverse order as removal.
Installation Service Points
]A[ Camshaft Sprocket Bolt Tightening.
]B[ Auto-tensioner Installation.
If the auto-tensioner rod is fully extended, set it in the retracted position with the following procedure.
1. Set the auto-tensioner in a vice.
2. Slowly close the vice to force the rod in until the set hole (A) of the rod is lined up with the set hole (B) of the cylinder.
3. Insert a wire [1.4 mm (0.055 inch) in diameter] into the set holes.
4. Remove the auto-tensioner from the vice.
]C[ Timing Belt Installation.
1. Move the timing mark of the crankshaft sprocket three teeth to slightly lower the piston below the top dead center on the compression stroke of the No. 1 cylinder.
CAUTION: If the camshaft sprocket is rotated with the piston at the top dead center on the compression stroke of the No. 1 cylinder, the valve and piston might interfere.
2. Line up the timing marks of the left bank camshaft sprockets.
3. Line up the timing marks of the right bank camshaft sprockets.
CAUTION: Since the camshaft sprocket readily turns because of spring action, use care to make sure that your finger is not caught.
4. Line up the timing marks of the crankshaft sprockets.
5. Install the timing belt on each sprocket in the following sequence.
(1) Install the timing belt on the crankshaft sprocket and then on the idler pulley, while tightening it to prevent slackness.
(2) Install the timing belt on the left bank camshaft sprocket.
(3) Install the timing belt on the water pump pulley, while taking up the slack.
(4) Install the timing belt on the right bank camshaft sprocket.
(5) Install the timing belt on the tensioner pulley.
6. Lightly press the tensioner pulley against the belt and temporarily tighten the center bolt.
7. Check to see that the timing marks of all the sprockets are in alignment.
8. Using a special tool, rotate the crankshaft a quarter of a turn counter-clockwise. Then rotate it back clockwise to verify that all the timing marks are in alignment.
9. Mount a special tool and torque wrench on the tensioner pulley.
10. Torque it to 4.4 Nm (3.3 ft. lbs.) with the torque wrench.
11. While holding the tensioner pulley in position, tighten the center bolt to the specified torque.
12. Rotate the crankshaft two turns clockwise and let it stand for approximately 5 minutes.
13. Check to see whether the metal wire inserted when the auto-tensioner was installed can be removed without any resistance.
If the metal wire can be removed without any resistance, it means that the belt is correctly tensioned. Therefore, remove the metal wire. In this condition, check that the projection of the rod of the auto-tensioner is within the standard value.
Standard value: 3.8 - 5.0 mm (0.150 - 0.196 inch)
14. If the metal wire cannot be removed easily, repeat the foregoing steps (9) through (12) until correct belt tension is obtained.
]D[ Engine Support Bracket.
1. Tighten bolts to specified torque in the sequence shown.
Post-installation Operation:
- Crankshaft Pulley.
INTAKE MANIFOLD PLENUM AND THROTTLE BODY
Removal
Follow removal steps outlined in illustration.
Installation
Installation in reverse order as removal.
INTAKE MANIFOLD AND FUEL PARTS
Removal
Follow removal steps outlined in illustration.
Installation
Installation in reverse order as removal.
Installation Service Points
]A[ O-Ring and Water Pipe Installation.
1. Wet the O-ring (with water) to facilitate assembly.
CAUTION: Keep the O-ring free of oil or grease.
]B[ Thermostat Installation.
1. Install the thermostat in the thermostat housing with its jiggle valve located at the top position.
]C[ Heater Inlet And Outlet Pipes.
1. Attach the outlet and inlet pipes in this order, one on the top of the other.
]D[ Sealant Application To Engine Coolant Temperature Sensor.
Specified sealant:
3M Nut Locking No. 4171 or equivalent
]E[ Sealant Application To Engine Coolant Temperature Gauge Unit.
Specified sealant:
3M Part No. 8660 or equivalent
]F[ 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.
]G[ 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 the 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.
]H[ 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 AND WATER PUMP
Removal
Follow removal steps outlined in illustration.
Installation
Installation in reverse order as removal.
Installation Service Points
]A[ O-ring And Water Pipe Installation.
1. Wet the O-ring (with water) to facilitate assembly.
CAUTION: Keep the O-ring free of oil or grease.
]B[ Exhaust Manifold Gasket Installation.
1. Install gaskets with cylinder number 1, 3 and 5 embossed on their top side to the rear bank and install those with cylinder number 2, 4 and 6 to the front bank.