Unit Repair

REMOVAL

Remove Battery ground cable

1. Remove air cleaner and hoses
2. Remove wiring harness connectors at the side of the distributor cap
3. Remove distributor cap
- Scribe a mark on the engine in line with the rotor.
- Note the position of the distributor housing in relation to the engine.

4. Remove distributor fixing nut and clamp
5. Remove distributor

INSPECTION AND REPAIR
Make necessary part replacements and/or repairs if excessive wear or damage is discovered during inspection.





Measure the air gap, using a thickness gage. If the measurement is outside the specified limits, the signal generator must be replaced with a new one.

Air gap: 0.2-0.4 mm (0.008-0.0016 in.)

Inspect the distributor cap for cracking, burning, corrosion, and wear.

Measure Pick-up coil resistance





- Connect ohmmeter (Middle scale) to either pickup coil lead and housing.

Standard: Infinite Ohms





If not as specified, replace the distributor.

- Connect ohmmeter to both pickup coil leads, flex leads by hand at connector to locate intermittent opens.

Standard: 500-1500 Ohms

If not as specified, replace the distributor.

INSTALLATION
1. Install distributor
- To ensure correct timing of the distributor it must be installed with the rotor correctly positioned as noted in the removal procedure.
- If the distributor shaft won't drop into the engine, insert a screwdriver into the hole for the distributor and turn the oil pump drive- shaft.

2. Install distributor fixing nut and clamp
3. Install distributor cap
4. Install wiring harness connectors
5. Install air cleaner and hoses
6. Set the ignition timing.

IGNITION TIMING ADJUSTMENT

WARNING
- To prevent possible personal injury from a moving vehicle or operating engine, do the following before performing the checks:
1. Engage the parking brake and block the wheels.
2. Place the manual transmission in neutral.

1. Refer to the "Important Vehicle Information" label located on the engine hood.
2. Refer to the "Driveability and Emissions" for information on the bypass timing mode.
3. With the engine control switch "OFF", connect the pickup lead of the timing light onto the number one spark plug. Use a jumper lead between the wire and plug or an inductive type pick up.
Do not pierce the wire or attempt to insert a wire between the boot and the wire. Connect the timing light power leads according to the manufacturer's instructions.
4. Follow all instructions on the Important Vehicle Information label. Start the engine, and aim the timing light at the timing mark. The line on the balancer or pulley will line up at the timing mark. If a change is necessary, loosen the distributor hold-down clamp bolt at the base of the distributor. While observing the mark with the timing light, slightly rotate the distributor until the line indicates the correct timing. Tighten the hold-down bolt, and recheck the timing.




5. Turn "OFF" the engine and remove the timing light. Reconnect the number one spark plug wire, if removed.

NOTE:
- With #1 cvi at T.D.C. as determined by positioning #3 cyl 0.7mm below #5 cyl, "0" reference line of painter must align with center of timing notch on torsional damper within 0.5mm after assembling securely.