cooling NISSAN PULSAR 1987 Workshop Manual
[x] Cancel search | Manufacturer: NISSAN, Model Year: 1987, Model line: PULSAR, Model: NISSAN PULSAR 1987Pages: 238, PDF Size: 28.91 MB
Page 3 of 238
CONTENTS
INTRODUCTION........................................ 5
VEHICLE IDENTIFICATION AND
GENERAL SPECIFICATIONS................. 7
GENERAL INFORMATION...................... 8
Tools and equipment ............................................. 8 Safety .................................................................... 10
General repair procedures..................................... 11
LUBRICATION AND MAINTENANCE... 14
Specifications......................................................... 14
How to grease and oil change .............................. 14
Service schedule ................................................... 17
WHEELS AND TYRES............................. 21
Specifications......................................................... 21
How to change a road wheel ................................ 21
Tire wear troubl e shooting ..................................... 22
Care and main tenance ......................................... 23
ENGINE TUNE-UP.................................... 25
Tune-up specifications ........................................... 25
Tune-up operat ions............................................... 25
ROADSIDE TROUBLE SHOOTING....... 32
Trouble shoot ing.................................................... 32
To check ignition and el ectrical system ................ 33
To check fuel system ............................................ 34
To check mechani cal system ................................ 35
ENGINE....................................................... 37
Specifications ........................................................ 37
Engine mechanical tr ouble shooting ...................... 39
Description ............................................................ 41
Engine and transaxle assembly ........................... 42
Manifolds ............................................................... 44 Camshaft, rocker arms and tappets..................... 48
Cylinder head........................................................ 50
Engine sump and oil pum p pickup pipe................ 54
Oil pump ............................................................... 55
Pistons, connecting rods and cylinder bores ........ 57
Crankshaft and bearings ...................................... 60
Flywheel /drive plate............................................... 63
Engine mountings.................................................. 64
Exhaust system .................................................... 66
COOLING AND HEATING SYSTEMS.... 68
Specifications ........................................................ 68 Cooling system trouble shooting ........................... 68
Heater and air conditioner trouble shooting ......... 69 Description ............................................................ 70
Radiator ................................................................ 70
Cooling fan ............................................................ 73
Thermost at............................................................ 75
Thermostat housing .............................................. 76
Water pump .......................................................... 76
Welch plugs .......................................................... 76
Heater unit, water valv e and controls ................... 77
Blower fan ............................................................. 80
Air condition ing ..................................................... 80
FUEL AND ENGINE MANAGEMENT ... 82
Specifications ........................................................ 82 Fuel and engine management trouble shooting ... 82
Description ............................................................ 84
Service precautions and procedures
..................... 86
System diagnosis and adjustments ...................... 89
Fuel supply components ....................................... 92
Air flow components .............................................. 98
Electronic components .......................................... 104
EMISSION CONTROL............................. 117
Introduction ........................................................... 117
Crankcase ventilati on system............................... 117
Evaporate control system..................................... 117
Air preheat system — 1.6 liter engines ................ 119
Exhaust control system ........................................ 120
CLUTCH...................................................... 121
Specifications........................................................ 121
Clutch trouble shooting......................................... 121
Description ............................................................ 122
Clutch unit and release mechanism..................... 123
Clutch pedal ......................................................... 124
Clutch c able.......................................................... 124
Clutch adjustments ............................................... 125
MANUAL TRANSAXLE AND
DRIVE SHAFTS......................................... 126
Specifications ........................................................ 126
Manual transaxle and drive shaft trouble shooting 126
Description............................................................ 128
Transaxle assembly.............................................. 129
Differential and final drive assembly ..................... 135
Gear lever assembly ............................................ 136
Drive shafts .......................................................... 137
AUTOMATIC TRANSAXLE....................... 140
Specifications........................................................ 140
Automatic transaxle trouble shooting.................... 140
Description............................................................ 141
Transaxle fluid ...................................................... 141
Brake band........................................................... 142
Kickdown cable .................................................... 142
Transaxle select or linkage ................................... 142
Neutral safety switch ............................................ 142
Transaxle assembly .............................................. 143
STEERING................................................. 145
PART 1. STEERING TROUBLE SHOOTING....145
Faults, causes and remedies................................ 145
PART 2. MANUA L STEERING......................... 147
Specifications ........................................................ 147
Description............................................................ 147
Steering wheel ...................................................... 147
Steering column.................................................... 148
Steering gear assembly ....................................... 149
PART 3. POWE R STEERING .......................... 152
Specifications........................................................ 152
Description............................................................ 152
In car adjustments, checks and minor repairs ..... 152
Steering wheel ...................................................... 153
Steering column.................................................... 153 Power steering pump ........................................... 153
Power steering gear assembly............................. 154
Page 10 of 238
10 General Information
If tools are to be stored for any length of time, it is
good policy to wipe them with an oily cloth.
Bladed screwdrivers should be checked for dam-
age to the tip. If necessary, the tip can be returned to
its original profile by careful grinding. Do not grind
screwdriver tips to a sharp point.
Hammer heads should be secure on their handles
and should be regularly checked for cracking or other
damage.
Chisels and punches should be checked for dam-
age or 'mushrooming' of the head. Any faults should
be rectified by grinding.
Hydraulic jacks should be regularly checked for
fluid leaks. Chassis stands and car ramps should be
checked for damage and cracks. Any equipment that
is suspect should not be used.
STORES
For routine maintenance, stores of automotive
oils, greases and additives should be kept on hand.
The following is a suggested list.
Engine oil.
Brake fluid.
Manual transmission or automatic transmission
oil — automatic transmission oil is also used in
the power steering system.
Rear axle oil.
Cooling system corrosion inhibitor/antifreeze.
Chassis grease.
High melting point grease, for hub bearings etc.
Penetrating oil or spray.
Kerosene or similar cleaning solvent.
Methylated spirits.
Oils and greases are available in handy pack size for
do-it-yourself lube jobs.
2. SAFETY
PERSONAL SAFETY
Safety when working on a motor vehicle is basical-
ly a matter of commonsense. Some safety precautions
to prevent personal in juries are as follows.
Raising a Vehicle
Always jack a vehicle on firm, level ground and at
the specified jacking points . Ensure that the wheels
remaining on the ground are fully chocked.
After raising the vehicle, place chassis stands
underneath and allow the weight of the vehicle to rest
on them. Do not use bricks, blocks of wood or similar
material.
NOTE: Never work under a vehicle which is
only supported by a jack.
Electrical System
Always disconnect the negative battery terminal
when working on any electrical components. Avoid
wearing metal watches, rings and chains which may
short across live terminals.
As battery gases are explosive, keep naked flames
and sparks clear of the work area. When connecting
and disconnecting jumper leads, use extreme caution
to avoid sparking.
Electronic Ignition Systems
Electronic ignition systems produce dangerous
high tension voltages in bo th the primary and second-
ary circuits which can be fatal. Exercise extreme
caution when working on or near any ignition system
components. Do not disconnect high tension leads
while the engine is running.
Work Area
Do not run the engine in a confined space. Ensure
that the work area is adequately ventilated.
Spilt oil or water should be cleaned immediately
to avoid the possibility of slipping.
Fuel System
Always disconnect the negative battery terminal
when working on any fuel components. Do not smoke.
Keep naked flames and sparks clear of the work area.
Do not siphon fuel using the mouth. Use a hand
pump or suitable siphon.
Do not attempt to repair a fuel tank by welding it.
This is an extremely hazardous procedure and should
be entrusted to a specialist.
Cooling System
To avoid scalding, use caution when releasing the
radiator cap on an engine wh ich is at normal operating
temperature. Turn the cap anti-clockwise to the first
stop and allow any pressure in the system to release.
When the pressure is released, remove the cap from
the radiator.
Brakes
As asbestos is used in some brake lining material,
avoid inhaling brake dust. Do not use compressed air
to remove the dust. Gentle brushing with a small
brush or using a vacuum cleaner with a hose attach-
ment are the safest methods of cleaning the brakes.
The above precautions also apply to the clutch plate
lining material.
Page 14 of 238
14
LUBRICATION AND MAINTENANCE
SPECIFICATIONS
CAPACITY AND GRADE
Engine:
Lubricant........................................... 15W-50 SF
Sump capacity including filter ........... 3.3 liters
Cooling system capacity............................ 6.0 liters
Manual transaxle:
Lubricant....................................... 80W-90 GL-4
Capacity ............................................... 2.7 liters
Automatic transaxle:
Lubricant.............................................. Dexron II
Capacity ............................................... 6.0 liters
Power steering:
Lubricant.............................................. Dexron II
Capacity ............................................... 1.0 liters
Manual steering lubricant ........ Castrol EPLl grease
Brake fluid type ................................................ Dot 4
1. HOW TO GREASE AND OIL CHANGE
(1) Run the front of the vehicle onto car ramps
and stop the engine. Chock the front wheels. (2) Raise the rear of the vehicle and place
chassis stands under the rear jacking points.
NOTE: It is best if the vehicle is kept as level
as possible to avoi d false readings when
checking the lubricant levels.
(3) Clean around the engine sump drain plug.
(4) Place a drain tin under the engine sump,
remove the engine sump drain plug and allow the
engine sump to completely drain.
NOTE: It is best to drain the engine sump
with the oil at operating temperature. How-
ever, if the oil is hot take care to avoid
scalding.
(5) Check that the sealing gasket on the sump
plug is in a serviceable condition. (6) When the engine sump has completely
drained, install and firmly tighten the sump drain plug.
Wipe around the plug after installation. (7) Place the drain tin under the oil filler,
remove the oil filter using a filter removal tool and
allow the residual engine oil to drain. Smear the
scaling ring of the new filter with engine oil and
lighten the filter by hand as per the instructions
supplied with the new filter.
NOTE: Before installing the new filter, en-
sure that the sealing gasket from the old
filter has not adhered to the filter sealing
surface on the engine.
(8) Remove the level checking plug from the
Location of the engine sump drain plug.
Removing the engine oil filter using a filter removal tool.
Page 35 of 238
Roadside Trouble Shooting 35
View showing the location of the fuel pump fuse and the EGI and fuel pump relays.
switch. When starting the engine, the fuel
pump will not operate until the oil pressure
is sufficient to extinguish the oil pressure
warning lamp. Therefore it will be necessary
to operate the starter motor for a longer
period than usual to start the engine.
(3) If the fuel pump cannot be felt operating,
check the fuel pump fuse located in the fuse panel
adjacent to the steering column.
If the fuel pump fuse is serviceable, refer to the
Fuel and Engine Management section for detailed
tests on the fuel pump.
(4) Check that all fuel hose connections are
secure.
(5) Remove the spark plugs and check for petrol
saturation of the electrodes which indicates flooding.
Thoroughly clean and dry the spark plugs before
replacement. Fully depress the throttle pedal and turn the
ignition switch to the start position. If the engine does
not start, proceed as follows.
Check that the MAP sensor hose is not blocked or split
and ensure that all electrical connections are clean and
secure.
If flooding persists, refer to the Fuel and Engine
Management section.
(6) Check that all EFI electrical wiring connec-
tors are clean and secure.
(7) Check that the MAP sensor vacuum hose is
securely connected at each end and is not split or
blocked.
4. TO CHECK MECHANICAL SYSTEM
The following check procedure assumes that the
starter motor will rotate the engine. If not, on manual
transaxle models, depress the clutch pedal to disen-
gage the engine from the tr ansaxle in case the fault lies
within the transaxle.
If the starter motor will not rotate the engine, it
will be necessary to remove the starter motor and
attempt to turn the engine over manually. This will
establish whether the fault lies with the starter motor,
which could be jammed or defective, or with the
engine, which could be seized or have broken internal
components such as connecting rods, pistons and
crankshafts etc.
If the starter motor is not at fault and the engine
will not rotate manually, refer to the Engine Mechan-
ical Trouble Shooting heading in the Engine section.
It should be noted that the only way that cylinder
compression can be accurately tested is with a com-
pression gauge. The method described in the following
procedure is only intended to give a rough indication
when checking for causes of engine breakdown,
(I) When the engine is cool, check for loss of
coolant from the cooling system.
If coolant loss is evident, check carefully for any
indication of external leakage. Remove the engine oil
dipstick and check for wate r contamination (emulsi-
fication) of the oil. When oil mixes with water it will
Ensure that all fuel connections are securely tightened.
Page 44 of 238
44 Engine
Rear three quarter view of the 1.8 liter engine and automatic transaxle assembly.
mountings. Lower the assembly onto the mountings
and tighten the mounting nuts and bolts.
(4) Install a new exhaust flange gasket.
(5) Fill the engine and transaxle with the correct
quantity and grade of lubricant. (6) Fill the cooling system as described in the
Cooling and Heating Systems section. (7) On models with power steering, fill the power
steering reservoir with the recommended fluid.
(8) Start and run the engine until it reaches the
normal operating temperatur e and check for fuel, oil
and coolant leaks.
4. MANIFOLDS
INLET MANIFOLD - 1.6 Liter Models
To Remove and Install
NOTE: Due to the high residual pressure
within the fuel system, it will be necessary to
depressurise the system before removing the
fuel supply components. Refer to the Fuel
and Engine Management section for the
correct procedure.
(1) Disconnect the negative battery terminal.
(2) Remove the wingnuts retaining the air
cleaner to the throttle body, lift the air cleaner
upwards slightly and disconnect the vacuum hoses. (3) Drain the cooling system as described in the
Cooling and Heating Systems section. (4) Loosen the hose clamps and disconnect the
engine coolant hoses from the rear of the manifold.
(5) Disconnect the small branch of the engine
ventilation hose from the rear of the inlet manifold. (6) On automatic transaxle models, disconnect
the kickdown cable from the throttle lever by releasing
the wire spring clip and re moving the cable end socket
from the ball.
(7) Turn the throttle lever to the full throttle
position. Using the slack in the throttle cable, release
the throttle cable end thr ough the slot provided.
Page 45 of 238
Engine 45
Installed view of the inlet manifold. 1.6 liter models. Air
cleaner removed.
(8) Remove the bolts retaining the throttle cable
bracket to the inlet manifold and place the bracket
with cable(s) attached to one side.
(9) Suitably mark the supply and return fuel
hoses and disconnect them from the throttle body.
(10) Suitably mark and disconnect the air pre-
heat, map sensor, charcoal canister and brake booster
vacuum hoses from the throttle body. (11) Disconnect the electrical connector from the
throttle body. (12) Remove the inlet manifold nuts and with-
draw the inlet manifold assembly. Discard the gasket. Installation is a reversal of the removal procedure
with attention to the following points:
(1) Ensure that all the carbon and old gasket
material is cleaned from the manifold and cylinder
head faces. (2) Check the face of the manifold for distortion
using a straight edge and a feeler gauge. (3) Use a new gasket and ensure that the mani-
fold retaining nuts are tightened to the specified
torque in a spiral pattern from the centre outwards. (4) Connect the vacuum hoses, the throttle cable
and where applicable, the kickdown cable. Adjust the
throttle cable as outlined in the Fuel and Engine
Management section and the kickdown cable as
described in the Automatic Transaxle section. (5) Fill the cooling system as described in the
Cooling and Heating Systems section. (6) Start the engine and check for air, fuel and
water leaks.
INLET MANIFOLD - 1.8 Liter Models
To Remove and Install
NOTE: Due to the high residual pressure
within the fuel system, it will be necessary to
depressurise the system before removing any
fuel supply components. Refer to the Fuel
and Engine Management section for the
correct procedure.
(1) Disconnect the negative battery terminal.
(2) Loosen the hose clamp and disconnect the
air inlet duct from the throttle body. (3) Suitably mark and disconnect the vacuum
hoses from the throttle body. (4) On automatic transaxle models disconnect
the kickdown cable from the throttle lever by releasing
the wire spring clip and re moving the cable and socket
from the ball. (5) Turn the throttle lever to the full throttle
position. Using the slack in the throttle cable, release
the throttle cable end thr ough the slot provided.
(6) Remove the bolts retaining the throttle cable
bracket to the inlet manifold and place the bracket
with cable(s) attached to one side. (7) Disconnect the wiring connectors from the
idle air control (IAC) valve and the throttle position
sensor (TPS).
(8) Disconnect the wiring connectors from the
fuel injectors and manifold air temperature (MAT)
sensor.
NOTE: A small screwdriver or similar tool
can be used to release the wire spring clips
on the injector connectors.
(9) Suitably mark and disconnect the fuel supply
and return lines from the fuel rail. (10) Remove the inlet manifold nuts and with-
draw the inlet manifold assembly. Discard the gasket. Installation is a reversal of the removal procedure
with attention to the following points:
View of the inlet manifold removed from the engine.
Page 47 of 238
Engine 47
Line drawing showing the dimensions for the fabrication of a camshaft drive belt adjusting tool.
(5) Release the clips securing the camshaft drive
belt outer cover to the inner cover and remove the
outer cover.
(6) Turn the engine in the direction of rotation
until the timing marks on the camshaft gear and the
inner cover are aligned and the timing marks on the
crankshaft pulley and the pointer on the inner timing
cover are also aligned.
(7) If the drive belt is to be reused, mark the
drive belt with an arrow to ensure that it is installed
in the original direction of rotation. (8) Remove the Allen head bolts securing the
crankshaft pulley to the crankshaft gear and remove
the pulley. (9) Loosen the water pump retaining bolts and
using the adjusting tool, rotate the water pump
housing to release the camsh aft drive belt tension.
NOTE: A drive belt tension adjusting tool
can be manufactured from a piece of 10 mm
thick steel to the dimensions given in the
illustration.
(10) Remove the inner cover lower retaining bolts
and maneuver the camshaft drive belt from the
camshaft and crankshaft gears. Do not rotate the
crankshaft or camshaft.
TO CHECK AND INSPECT
(1) Inspect the drive belt for any signs of wear,
damaged teeth or torn backing. Renew the belt if it is
contaminated by oil. Do not wash or clean a drive belt
in solvents. Any slight contamination may be wiped
off using a dry cloth.
NOTE: If the drive belt is contaminated
with oil, the crankshaft and camshaft oil
Dismantled view of the camshaft drive belt
components.
seals must be checked and any oil leak
rectified prior to installing a new drive belt.
(2) Check the water pump for rough or exces-
sively noisy operation. Ensure that the assembly slides
smoothly in the cylinder bloc k and that the seal is not
leaking. Refer to the Cooling and Heating Systems
section if it is necessary to renew the water pump
assembly. (3) Check the water pump, camshaft and crank-
shaft timing gears for any wear or damage.
Check the drive belt for the illustrated faults.
Page 49 of 238
Engine 49
Dismantled view of the camshaft housing and components.
(10) If the measurement is not within Specifica-
tions, check the retaining plate and the retaining plate
groove in the camshaft for wear or scoring after
dismantling. Renew the defective parts as necessary
on assembly. (11) Disconnect the lower radiator hose and drain
the cooling system.
NOTE: If the coolant is to be reused, drain
the coolant into a clean container.
(12) Remove the bolts securing the camshaft
drive belt inner cover to the camshaft housing. (13) Remove the cylinder head bolts in the re-
verse order of the tighten ing sequence, backing off
each bolt a quarter of a turn then half a turn at a time
until the bolts are loose.
NOTE: Do not loosen the cylinder head
bolts while the engine is warm as distortion
of the cylinder head could result.
(14) Remove the cylinder head bolts and lift the
camshaft housing from the cylinder head. (15) The rocker arms, thrust pads and tappet
assemblies can now be removed from the cylinder
head. Number a rack from 1 to 8 and keep each
assembly in order so that they can be returned to their
original positions.
(16) From the distributor drive end of the cam-
shaft housing, remove the bolts securing the camshaft
retaining plate to the camshaft housing and remove
the retaining plate. (17) Withdraw the camshaft from the camshaft
housing taking care to supp ort the camshaft to avoid
scoring the inner surfaces of the camshaft bearings.
(18) With a pointed drift, tap a small hole in the
front face of the oil seal. Insert a self tapping screw in
the hole and using a pair of pliers, pull on the screw
to remove the oil seal from the housing. Discard the
oil seal.
TO CLEAN AND INSPECT
(1) Wash all parts in cleaning solvent and dry
with compressed air. Ensure that all oil ways in the
camshaft and rocker arms are free from obstruction.
(2) Check the camshaft lobes, the rocker arms. the thrust pads and the ta
ppet assemblies for pitting
and wear. The tappet assemblies are non-serviceable
and should be renewed as an assembly if wear is
apparent or internal damage is suspected.
(3) Support the camshaft at each end on Vee
blocks and using a dial gauge with its plunger bearing
on the centre journal, rotate the camshaft and check
for bend. (4) Using micrometers, measure the outside of
each camshaft journal and the inside of each camshaft
tunnel in the camshaft housing. Compare these mea-
surements to Specifications and renew defective parts
as necessary. (5) Check the retaining plate and the retaining
plate groove in the camshaft for wear and scoring.
Renew defective parts as necessary.
Dismantled view of the valve operating components.
TO INSTAL
Installation is a reversal of the removal procedure
with attention to the following points:
(1) Lubricate the lip of a new oil seal with engine
oil and position the seal squarely in the camshaft
housing. Ensure that the li p of the seal faces towards
the inside of the camshaft housing. Tap around the
edge of the seal with a soft faced hammer until the seal
is fully seated in the recess in the camshaft housing. (2) Apply clean engine oil to the camshaft bear-
ings and camshaft journals. Insert the camshaft into
position taking care not to damage the bearings with
the edges of the cam lobes or journals. (3) Apply engine oil to the camshaft retaining
plate and position it in the groove in the camshaft.
Install the retaining bolts and tension the bolts to the
specified torque.
Page 50 of 238
50 Engine
(4) Ensure that the tappet assemblies are full of
clean engine oil and insert the tappets in their
respective bores in the cylinde r head. Install the thrust
pads to the top of each valve assembly ensuring that
they are returned to their original location.
(5) Coat the contact surfaces of the rocker arms
with molybdenum disulphide grease and install the
rocker arms to their origin al locations on the cylinder
head. (6) Clean the mating surfaces of the camshaft
housing and cylinder head. Apply a bead of Loctite
515 to the cylinder head and camshaft housing mating
surfaces. Take care that no sea lant is forced into the
oil passages and install the camshaft housing to the
cylinder head.
(7) Install new cylinder head bolts and lubricate
the bolts and washers with oil.
(8) Apply an initial torque to the cylinder head
bolts of 25 Nm in the corr ect sequence as shown in
the illustration under the Cylinder Head heading.
Further tighten the head bolts in the correct sequence,
in three separate 60 degree stages. Refer to Specifica-
tions. (9) Install the bolts securing the camshaft
drive
belt inner cover to the camshaft housing. (10) Install the camshaft timing gear to the cam-
shaft ensuring that it is correctly located. Tighten the
camshaft timing gear retain ing boll to the specified
torque. (11) Install and adjust the camshaft drive belt as
described under the previous heading. (12) Install the distributor. Refer to the Fuel and
Engine Management section.
(13) Connect the lower radiat or hose and fill the
cooling system with the required coolant. Refer to the
Cooling and Heating Systems section if necessary. (14) Start and run the engine until normal oper-
ating temperature is attained and tighten the cylinder
head bolts another 30-50 degrees in the correct
sequence, ensuring that the tension does not exceed
135 Nm.
TO RENEW CAMSHAFT OIL SEAL,
CAMSHAFT INSTALLED
(1) Remove the camshaft drive belt from the
camshaft timing gear as described under the previous
heading.
(2) Remove the camshaft housing top cover
retaining bolts, remove the cover and discard the
gasket.
(3) Use an open end spanner to hold the cam-
shaft between the inlet and exhaust lobes of number
four cylinder and remove the camshaft timing gear
retaining bolt and the camshaft timing gear. (4) With a pointed drift, tap a small hole in the
front face of the oil seal. Insert a self tapping screw in
the hole and using a pair of pliers, pull on the screw
to remove the oil seal from the housing.
(5) Clean the seal recess and the camshaft sea!
running surface. (6) Lubricate the lip of a new oil seal with engine
oil and slide the seal over the camshaft. Ensure that
the lip of the seal faces to wards the inside of the
camshaft housing. Tap evenly around the edges of the
seal until it is fully seated in the camshaft housing.
(7) Install the camshaft timing gear to the cam-
shaft, ensuring that it is co rrectly located. Tighten the
camshaft timing gear retain ing bolt to the specified
torque. Do not allow the camshaft to rotate while
tightening the bolt. (8) Install and adjust the drive belt as described
under the previous heading. Ensure that the timing
marks are aligned. (9) Install the camshaft hou sing top cover using a
new gasket. Tighten the retaining bolts to the specified
torque.
7. CYLINDER HEAD
Special Equipment Required:
To Dismantle and Assemble — Valve spring com-
pressor
To Inspect — Dial gauge and straight edge
To Install — Drive belt adjusting tool
TO REMOVE AND INSTAL
NOTE: Due to the high residua! pressure
within the fuel system, it will be necessary to
depressurize the system before removing any
fuel supply components. Refer to the Fuel
and Engine Management section for the
correct procedure.
Allow the engine to cool prior to the
removal of the cylinder head to prevent
possible distortion of the cylinder head.
(1) Disconnect the negative battery terminal and
remove the nuts securing the earth wires to the
cylinder head bolts.
(2) Remove the camshaft drive belt as previ-
ously described.
(3) Disconnect the lower radiator hose and drain
the cooling system. Refer to the Cooling and Heating
Systems section if necessary. (4) Remove the alternator adjusting bracket
mounting bolt and insulating washers from the inlet
manifold. Loosen the adjusting bolt at the alternator
and slide the bracket away from the cylinder head. (5) Disconnect the upper radiator hose, coolant
by-pass hose and the heater hose from the thermostat
housing and on 1.6 liter m odels, the coolant hoses
from the inlet manifold. (6) Disconnect the electrica l connectors from the
throttle body, fuel injectors, coil, distributor and on
1.8 liter models, the MAT sensor. (7) Disconnect the oxygen sensor wiring connec-
tor and remove the wiring connectors from the
Page 51 of 238
Engine 51
coolant temperature sensor and temperature sender
switch located in the thermostat housing.
(8) Remove the bolt securing the wiring clamp
to the rear of the manifold and maneuver the wiring
away from the cylinder head and the inlet manifold.
(9) Disconnect the throttle cable and on auto-
matic transaxle models, the kickdown cable from the
throttle body linkage. (10) Remove the bolls securing the throttle cable
bracket to the inlet manifold and place the bracket
and cable(s) to one side.
(11) Mark the fuel supply and return hoses to
ensure correct installation and disconnect the hoses
from the fuel rail or throttle body. Plug the hoses to
prevent the loss of fuel or the entry of dirt. (12) Mark the vacuum hoses connected to the
inlet manifold and throttle body to ensure correct
installation and disconnect the hoses. (13) Remove the nuts securing the engine pipe to
the exhaust manifold and separate the pipe from the
manifold. (14) Remove the oxygen sensor from the exhaust
manifold. Refer to the Fuel and Engine Management
section if necessary. (15) Remove the distributor and coil as described
in the Fuel and Engine Management section. (16) Disconnect the engine breather hoses from
the camshaft housing and cams haft housing top cover.
(17) Remove the bolts retaining the top cover to
the camshaft housing and remove the top cover. (18) Using an open end spanner, hold the cam-
shaft between the inlet and exhaust lobes of number
four cylinder and remove the camshaft timing gear
retaining bolt and the camshaft timing gear.
(19) Remove the bolts securing the camshaft
drive belt inner cover to the camshaft housing. (20) Loosen the cylinder head bolts in the reverse
order of the tightening sequence, backing off each bolt
a quarter turn then half a turn at a time until the bolts
are loose.
NOTE: Do not loosen the head bolts while
the engine is warm as distortion of the
cylinder head could result.
(21) Remove the cylinder head bolts and lift the
camshaft housing from the cylinder head. (22) Remove the cylinder head and gasket from
the cylinder block. Installation is a reversal of the removal procedure
with attention to the following points:
(1) Thoroughly clean the gasket surfaces of the
cylinder head, cylinder block and camshaft housing
and check all mating surfaces with a straight edge.
Ensure that all the oilways are clean and free of any
foreign material and lightly oil all operating parts with
engine oil.
(2) Install new gaskets throughout during
assem-
bly.
View of the cylinder head showing the bolt tightening
sequence.
(3) Ensure that the cylinde r head and gasket are
located correctly on the dowels on the cylinder block
face. The head gasket is marked TOP to aid in correct
installation. (4) With the cylinder head and gasket in posi-
tion on the cylinder block, apply an even smear of
Loctite 515 to the cylinder head and camshaft housing
mating surfaces. Take care that no sealant is forced
into the oil passages. (5) Install new cylinder head bolts and lubricate
the bolts and washers with engine oil,
(6) Apply an initial torque to the cylinder head
bolts of 25 Nm in the sequence shown in the
illustration. Further tighten the head bolts in the same
sequence in three separate 60 degree stages. Refer to
Specifications. (7) Install the bolts secur ing the camshaft drive
belt inner cover to the camshaft housing. Install the
camshaft timing gear and tighten the retaining bolt to
the specified torque. (8) Install and adjust the camshaft drive belt as
previously described. (9) Install the distributor, coil and oxygen sensor
as described in the Fuel and Engine Management
section.
(10) Using a new gasket, connect the engine pipe
to the exhaust manifold flange, coat the nuts with an
anti-seize compound and install and tighten the nuts
to
the specified torque. (11) Connect all hoses and electrical wiring dis-
connected during the removal of the cylinder head.
Ensure that all the hoses are returned to their original
locations. (12) Connect the throttle cable and where appli-
cable, the kickdown cable. Adjust the cables as
described in the Fuel and Engine Management section
and the Automatic Transaxle section. (13) Check the engine oil fo r correct level on the
dipstick and for dilution. Change the engine oil and
filter if necessary. (14) Fill the cooling system as described in the
Cooling and Heating Systems section. (15) Start the engine and check for oil or water