Distributor: Service and Repair
DISTRIBUTOR REMOVAL
1. DISCONNECT NEGATIVE TERMINAL CABLE FROM BATTERY.
CAUTION: Work must not be started for at least 90 seconds from the time the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery.
2. DISCONNECT DISTRIBUTOR CONNECTOR.
3. DISCONNECT HIGH-TENSION CORDS FROM DISTRIBUTOR.
- Disconnect the 7 high-tension cords from the distributor.
NOTE: Pulling on or bending the cords may damage the conductor inside.
4. REMOVE DISTRIBUTOR.
(a) Remove the nut.
(b) Pull out the distributor.
(c) Remove the O-ring from the distributor housing.
DISTRIBUTOR DISASSEMBLY
1. REMOVE HEAT INSULATOR .
- Remove the 3 screws and heat insulator.
2. REMOVE DISTRIBUTOR CAP.
- Loosen the 3 bolts, and remove the distributor cap and O-ring.
3. REMOVE ROTOR.
- Remove the 2 screws and rotor.
DISTRIBUTOR INSPECTION
INSPECT SHAFT.
- Turn the shaft and check that it is not rough or worn.
^ If it feels rough or worn, replace the distributor housing assembly.
DISTRIBUTOR ASSEMBLY
1. INSTALL ROTOR.
(a) Align the hollow of the signal rotor with the protrusion of the rotor.
(b) Install the rotor with the 2 screws.
2. INSTALL DISTRIBUTOR CAP.
(a) Install a new O-ring to the distributor housing.
(b) Install the distributor cap with the 3 bolts.
3. INSTALL HEAT INSULATOR.
- Install the heat insulator with the 3 screws.
DISTRIBUTOR INSTALLATION
1. REMOVE NO.3 TIMING BELT COVER.
(a) Remove the oil filler cap.
(b) Using a 5 mm hexagon wrench, remove the 6 bolts and timing belt cover.
2. SET NO.1 CYLINDER TO TDC/COMPRESSION.
(a) Turn the crankshaft pulley, and align its groove with timing mark "0" of the No.1 timing belt cover.
(b) Check that the timing marks of the camshaft timing pulleys and No.4 timing belt cover are aligned. If not, turn the crankshaft 1 revolution (360°) and align the mark as above.
3. INSTALL DISTRIBUTOR.
(a) Install a new O-ring to the distributor housing.
(b) Apply a light coat of engine oil on the O-ring.
(c) Align the marks of the drive gear and distributor housing.
(d) Insert the distributor, aligning the protrusion of the flange with that of the stud bolt on the cylinder head.
(e) Install the distributor with the nut. Lightly tighten the nut.
4. REINSTALL NO.3 TIMING BELT COVER.
(a) Using a 5 mm hexagon wrench, install the timing belt cover with the 6 bolts.
(b) Install the oil filler cap.
5. CONNECT HIGH-TENSION CORDS TO DISTRIBUTOR.
- Connect the 7 high-tension cords to the distributor.
Firing order: 1-5-3-6-2-4
6. CONNECT DISTRIBUTOR CONNECTOR.
7. CONNECT NEGATIVE TERMINAL CABLE TO BATTERY.
8. WARM UP ENGINE.
- Allow the engine to warm up to normal operating temperature.
9. CONNECT TACHOMETER AND TIMING LIGHT TO ENGINE.
Connect the tester probe of a tachometer to terminal IG- of the data link connector (DLC1).
NOTE:
^ Never allow the tachometer terminal to touch ground as it could result in damage to the igniter and/or ignition coil.
^ As some tachometers are not compatible with this ignition system, we recommend that you confirm the compatibility of your unit before use.
10. CHECK IDLE SPEED.
(a) Race the engine speed at 2,500 rpm for approx. 90 seconds.
(b) Check the idle speed.
Idle speed: 700 ± 50 rpm
11. ADJUST IGNITION TIMING.
(a) Using a jumper wire or special service tool (SST 09843-18020), connect terminals TE1 and E1 of DLC1.
(b) Using a timing light, check the ignition timing.
Ignition timing: 10° ± 2°BTDC @ idle
(Transmission in neutral position)
^ If not within specs, adjust ignition timing as follows:
(c) Loosen the nut, and adjust by turning the distributor.
Ignition timing: 10°BTDC @ idle
(Transmission in neutral position)
(d) Tighten the nut, and recheck the ignition timing.
Torque: 19 Nm (14 ft.lb)
(e) Remove the jumper wire or SST from DLC1.
12. FURTHER CHECK IGNITION TIMING.
HINT: The timing mark moves in a range between 7° and 19°.
Ignition timing: 7° - 19°BTDC @ idle
(Transmission in neutral position)
13. DISCONNECT TACHOMETER AND TIMING LIGHT FROM ENGINE.