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

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1. 2. 3. 4. 5. Drain the coolant and disconnect the upper radiator hose. Remove the breather hose (between the air cleaner and the rocker cover). Remove the air-intake hose. Remove the vacuum hose, fuel hose and coolant hose. Remove the cables from the spark plugs. The cables should be removed by holding the boot portion. Remove the ignition coil. Remove the surge tank. Remove the intake manifold. Remove the heat protector and exhaust manifold assembly Remove the coolant pump pulley and the crankshaft pulley. Remove the timing belt cover. 6. 7. 8. 9. 10. 11. Zoom Sized for Print 12. Move the timing belt tensioner pulley toward the coolant pump and temporarily secure it. 13. Remove the timing belt. 14. Remove the rocker cover. 15. Remove the cylinder head assembly. The cylinder head bolts should be removed using Special Tool, Cylinder Head Bolt Wrench (09221-21000), in the sequence as shown in the illustration. 16. Remove the gasket pieces from the cylinder block top surface and cylinder head bottom surface. NOTE: 1. Make sure that the gasket pieces do not fall in to the engine. INSPECTION 1. Check the cylinder head for cracks, damage and coolant leakage. 2. Remove scale, sealing compound and carbon deposits completely. After cleaning oil passages, apply compressed air to make certain that the passages are not clogged. 3. Check the cylinder head surface for flatness using a straight edge in the direction of A, B, …as shown. If flatness exceeds service limit in any direction, replace the cylinder head, or lightly machine the cylinder head surface. Cylinder head flatness Standard value: Less than 0.03 mm (0.0012 inch) Limit: 0.08 mm (0.0031 inch) REASSEMBLY 1. Clean all gasket surfaces of the cylinder block and the cylinder head. 2. Install a new cylinder head gasket onto the cylinder head assembly. Do not apply sealant to the gasket and do not reuse the old cylinder head gasket.

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DISASSEMBLY STEP 1. Unscrew knob and remove spring. Unsnap shift boot from neck of shifter. STEP 2. Lift up small carpet piece in rear of console. Remove bolt holding console to the car. TOOLS: Socket drive Extension 10mm socket STEP 3. Unclip (2) side panels from the front of the console. STEP 4. Remove (2) bolts securing console to center dash. TOOLS: Socket drive Extension 10mm socket STEP 5. Remove cigarette lighter/12V accessory panel and unclip wiring harness from terminals. Tabs on harness connections must be pressed to release grasp on electrical terminals. TOOL: Trim Panel Removal Tool STEP 6. Unclip trim piece near parking brake. TOOL: Trim Panel Removal Tool STEP 7. Remove console from car. STEP 8. Remove clip holding cable to shifter and slide cable off of pin. TOOL: Trim Panel Removal Tool STEP 9. Unclip ball-joint attachement on lower cable by spreading spring retainer. STEP 10. Unscrew (4) bolts from shifter base. TOOLS: Socket drive Extension 12mm socket 4 STEP 11. Gently pry edges of shifter retainers to allow removal from shifter base. TOOL: Screwdriver STEP 12. Remove shifter base from car. STEP 13. Slide out metal inserts from base bushings and remove rubber bushing. Repeat for all 4 corners. TOOL: Screwdriver STEP 14. Carefully cut off push-nut. TOOLS: Safety Glasses Rotary-tool w/ cut-off wheel STEP 15. Remove side arm assembly and spring from shifter base. Note orientation of spring. STEP 16. Squeeze locking tabs of shifter collar towards the center of the base. NOTE: It may be helpful to use a wide-blade screwdriver to pry tabs inward. Use caution not to excessively damage tabs. TOOLS: Pliers Wide-blade screwdriver STEP 17. Remove shifter collar. STEP 18. Remove rubber retaining ring.

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1. To check system operation, turn ignition on. Depress release button on side of gearshift lever. 2. With brake pedal released, gearshift lever should not move from Park. Depress brake pedal. With release button depressed, gearshift lever should now move from Park. 3. If shift lock system operation is not as specified, check brakelight switch and shift lock solenoid. See BRAKELIGHT SWITCH and SHIFT LOCK SOLENOID under COMPONENT TESTS. If necessary, check wiring and ground connections. See WIRING DIAGRAMS . KEY LOCK SYSTEM 1. With gearshift lever in any gear except Park, ensure ignition key cannot be turned to LOCK position. Place gearshift lever in Park. Ensure ignition key can now be turned to LOCK position. 2. If key lock system operation is not as specified, check key lock solenoid. See KEY LOCK SOLENOID under COMPONENT TESTS. If necessary, check wiring and ground connections. See WIRING DIAGRAMS .

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DISASSEMBLY 1. Using a tool remove the cylinder head bolts in the order shown in the illustration. 2. Using the special tool (09222-28000, 09222-28100), remove the valve retainer lock. Next remove the spring retainer, valve spring, spring seat and valve. Arrange these parts so that they can be reinstalled in their original positions. 3. Remove the valve stem seals with pliers. Do not reuse the valve stem seals. INSPECTION CYLINDER HEAD 1. Check the cylinder head for cracks, damage and coolant leakage. If cracked, replace the cylinder head. 2. Remove scale, sealing compound and carbon deopsits completely. After cleaning the oil passages, apply compressed air to verify that the passages are not clogged. 3. Check the cylinder head surface for flatness in the direction as shown in the illustration. If flatness exceeds the service limit in any direcftion, either replace the cylinder head or machine the cylinder head matching surface lightly. Flatness of cylinder head gasket surface Standard : Less than 0.03 mm (0.0012 in.) Limit : 0.2 mm (0.008 in.) VALVES 1. Using a wire brush, clean the valve thoroughly. 2. Check each valve for wear, damage and distortion of the head and the stem at B position. Replace, if necessary. If stem end, A, is hollowed out or worn, resurface as necessary. This correction must be limited to a minimum. Also resurface the valve face. Replace the valve if the margin has decreased to less than the service limit.

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1. Disconnect the negative(-) battery terminal. 2. Remove the head lamp mounting bolts (2EA), then disconnect the lamp connectors. 3. Installation is the reverse of removal.