Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Testing and Inspection Component Inspection CRANKSHAFT POSITION SENSOR (POS) 1. Loosen the fixing bolt of the sensor. 2. Disconnect crankshaft position sensor (POS) harness connector. 3. Remove the sensor. 5. Check resistance as shown in the figure. 6. If NG, replace crankshaft position sensor (POS). REMOVAL 1. 2. 3. 4. 5. 6. Remove the rocker cover. Remove the front right side tire and wheel using power tool. Remove the RH splash shield using power tool. Remove the auxiliary drive belt. Remove the coolant overflow reservoir tank. Remove the IVTC (intake valve timing control) cover by cutting the sealant using the Tool. Loosen the bolts in the order shown. 7. Set the No.1 cylinder at TDC on its compression stroke with the following procedure: a. Open the splash cover on RH under cover.

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CAUTION: – Do not bend or twist timing belt. – After removing timing belt, do not turn crankshaft and camshaft separately because valves will strike piston heads. – Make sure that timing belt, camshaft sprocket, crankshaft sprocket and belt tensioner are clean and free from oil and water. – Installation should be carried out when engine is cold. Removal 1. Jack up the vehicle front and support with safety stand. 2. Remove engine under cover. 3. Remove front RH wheel and engine side cover. 4. Drain engine coolant from radiator. 5. Remove the following belts. – Compressor drive belt – Generator drive belt – Power steering pump drive belt Timing Marks 6. Set No. 1 piston at TDC of its compression stroke. 7. Loosen crankshaft pulley bolt. 8. Remove crankshaft pulley using a suitable puller. 9. 10. 11. 12. 13. Remove radiator upper hose and water inlet hose. Remove compressor drive belt idler bracket. Remove water pump pulley. Remove breather pipe from timing belt front upper cover. Remove timing belt front covers.

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REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the distributor electrical connector. 3. Remove the two distributor cap screws and the distributor cap, then remove the distributor rotor. Position the distributor cap and spark plug wire set out of the way. 4. Rotate the engine until the number 1 piston is at the Top Dead Center (TDC) position on the compression stroke. 5. Remove the distributor hold-down bolt. 6. Remove the distributor. INSTALLATION NOTE: Before installation check that the number 1 cylinder is at TDC on the compression stroke. 1. Match up the alignment marks on the distributor shaft and distributor housing. 2. Apply engine oil to the O-ring on the distributor. 3. Install the distributor while making sure to engage the drive gear into the camshaft distributor drive gear. 4. Make sure the distributor rotor points to the number 1 wire tower. If the distributor rotor is misaligned, pull the distributor out and rotate the distributor shaft to the next tooth. Repeat this step until the distributor rotor is aligned with the number 1 wire tower. 5. Install the distributor rotor, distributor cap and the distributor cap screws. 6. Connect the distributor electrical connector. 7. Temporarily tighten the distributor hold-down bolt. 8. Connect the battery ground cable. 9. Adjust the ignition timing. 10. Tighten the distributor hold-down bolt to 19-25 Nm (14-18 lb ft).

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VALVE LASH (CLEARANCE) 1. Remove negative cable at battery. 2. Remove cylinder head cover. Zoom Sized for Print 3. Using 17 mm socket, turn crankshaft pulley clockwise until “V” mark (in white paint) on pulley aligns with “O” (zero) calibrated on timing belt cover. 4. Remove distributor cap and check rotor position. If it is positioned as shown in figure (i.e. No.1 piston is at Top Dead Center (TDC) of compression stroke), check valve lashes at valves (1), (2), (5) and (7). If it is at ignition position of No.4 cylinder, check valve lashes at valves (3), (4), (6) and (8). NOTE: When checking valve clearance, insert thickness gauge between camshaft and cam-riding face of rocker arm.

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1. Remove drive belts and drive pulleys from crankshaft and water pump. Remove timing belt covers. To align timing marks, rotate engine clockwise so No. 1 cylinder is at TDC of compression stroke. Ensure camshaft sprocket timing marks align with upper surface of rocker cover. Dowel pin of camshaft sprocket should be pointing upward. See Fig. 1 and Fig. 2 . 2. Remove timing belt auto tensioner. If reusing timing belt, place mark on timing belt to indicate direction of belt rotation. Remove timing belt. Remove camshaft sprockets. 3. Remove plug at left side of block and insert a screwdriver to hold left counterbalance shaft in position.
Screwdriver will have to be inserted at least 2.36″ (60 mm). Remove oil pump sprocket nut and sprocket. See Fig. 2 . 4. Loosen right counterbalance shaft sprocket mounting bolt. Remove tensioner “B” and timing belt “B”. See Fig. 2 . Remove crankshaft sprocket “B” from crankshaft.