Installation

COMPONENTS FOR REMOVAL AND INSTALLATION

1. INSTALL CAMSHAFT POSITION SENSORS TO DISTRIBUTOR HOUSINGS.
- Install the camshaft position sensor with the bolt and screw.
- Install the 2 camshaft position sensors.

Torque: 6.4 Nm (56 in lb)

HINT:
- The RH distributor housing is marked with "R".
- The LH distributor housing is marked with "L".

2. INSTALL RH DISTRIBUTOR HOUSING.
- Install the distributor housing with the 3 bolts.

Torque: 18 Nm (13 ft lb)

HINT:
- The RH distributor housing is marked with "R".
- Each bolt length is indicated in the illustration.

Bolt length:
A: 38 mm (1.50 in)
B: 96 mm (3.78 in)

3. INSTALL LH DISTRIBUTOR HOUSING.
- Install the distributor housing with the 3 bolts.

Torque: 18 Nm (13 ft lb)

HINT:
- The LH distributor housing is marked with "L."
- Each bolt length is indicated in the illustration.

Bolt length:
A: 38 mm (1.50 in)
B: 80 mm (3.15 in)

4. INSTALL DISTRIBUTOR ROTORS.
- Align the protrusion of the distributor rotor with the groove the camshaft timing pulley.
- Install the distributor rotor with the 2 bolts.
- Install the 2 distributor rotors.

Torque: 3.8 Nm (34 in lb)

5. INSTALL DISTRIBUTOR CAPS.
- Install the distributor cap with the 3 bolts.
- Install the 2 distributor caps.

Torque: 3.8 Nm (34 in lb)

6. CONNECT HIGH-TENSION CORDS TO DISTRIBUTOR CAPS.
- Connect the 10 high-tension cords.

NOTICE: Connect the high-tension cord by pressing on the correct place as shown in the illustration.
- If not done this way, the high-tension cord will interfere with the camshaft timing pulley.

7. INSTALL RH NO.2 TIMING BELT COVER.
- Install the 4 gaskets to the timing belt cover.
- Install the wire grommet to the timing belt cover.
- Fit the timing belt cover, matching it with the hydraulic pump.
- Fit the timing belt cover holes, matching them with the 2 grommets on the distributor cap.
- Install the timing belt cover with the 5 bolts.

Torque: 18 Nm (13 ft lb) for 12 mm head

HINT (for 12 mm head): Use bolts 106 mm (4.17 in) in length.

- Install the wire clamp to the timing belt cover.

- Except Calif.:
- Install the camshaft position sensor connector to the ignition coil bracket.

8. INSTALL LH NO.2 TIMING BELT COVER.
- Install the 2 gaskets to the timing belt cover.
- Run the camshaft position sensor wire through the timing belt cover hole.
- Fit the timing belt cover, matching it with the hydraulic pump.
- Fit the timing belt cover holes, matching them with the 2 grommets on the distributor cap.
- Install the timing belt cover and connector bracket with the 3 bolts.
- Install the wire grommet to the timing belt cover.
- Install the camshaft position sensor connector to the connector bracket.

9. INSTALL DRIVE BELT IDLER PULLEY.
- Install the idler pulley and cover plate with the bolt.

Torque: 37 Nm (27 ft lb)

10. CONNECT RADIATOR HOSE TO WATER INLET.

11. INSTALL RH NO.3 TIMING BELT COVER.
- Install the 3 gaskets to the timing belt cover.
- Fit the portion A of the timing belt cover, matching it with the lower high-tension cord cover.
- Install the timing belt cover with the 4 bolts.

12. INSTALL LH NO.3 TIMING BELT COVER.
- Install the 3 gaskets to the timing belt cover.
- Install the cord grommet to the high-tension cord (from the LH ignition coil).
- Install the cord grommet to the timing belt cover.
- Fit the portion A of the timing belt cover, matching it with the lower high-tension cord cover.
- Install the timing belt cover with the 4 bolts.

13. INSTALL RH ENGINE WIRE COVER.
- Fit portions A and B of the engine wire cover, matching them with the lower high-tension cord cover and No.3 timing belt cover.
- Install the timing belt cover with the bolt.

14. INSTALL LH ENGINE WIRE COVER.
- Connect portions A and B of the engine wire cover to the wire brackets.
- Set the vacuum switching valve (VSV) for the fuel pressure wire in original position.
- Fit portions C and D of the engine wire cover, matching them with the lower high-tension cord cover and No.3 timing belt cover.
- Install the timing belt cover with the 2 bolts.

15. INSTALL INTAKE AIR CONNECTOR.
- Connect the end portions of the intake air connector to the throttle body and air cleaner hose.
- Tighten the 2 hose clamps.
- Install the bolt holding the intake air connector to the cylinder head cover.

- Connect the following hoses:
- Air hose to Idle Air Control (IAC) valve
- Air hose (from air control valve on PS pump) to intake air connector
16. CONNECT NEGATIVE (-) TERMINAL CABLE TO BATTERY.
17. FILL ENGINE WITH COOLANT.
18. WARM UP ENGINE.
- Allow the engine to warm up to normal operating temperature.

19. CONNECT TACHOMETER AND TIMING LIGHT TO ENGINE.
- Connect the tester probe of a tachometer to terminal IG(-) of the DLC1.

HINT: Set the tachometer to the 4-cylinder range.

NOTICE:
- 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.

20. CHECK IGNITION TIMING.
- Using SST 09843-18020, connect terminals TE1 and E1 of the DLC1.

- Connect the tester probe of a timing light to the high-tension cord for No.6 cylinder.

- Using a timing light, check the ignition timing.

Ignition timing: 8 - 12° BTDC @ idle
(Transmission in neutral position)

- If the ignition timing is not as specified, check that following conditions are normal:
- Throttle valve fully closed
- Continuity between terminals IDL1 and E2 of the throttle position sensor
- Valve timing

- Remove the SST from the DLC1.
21. DISCONNECT TACHOMETER AND TIMING LIGHT FROM ENGINE.

22. INSTALL UPPER HIGH-TENSION CORD COVER.
- Fit portion A of the upper high-tension cord cover matching the top of the lower high-tension cord cover.
- Push the front side of the upper high-tension cord cover, and fit the front side claw groove of the upper high -tension cord cover to the claw of the lower high -tension cord cover.
- Install the upper high-tension cord cover with the 2 bolts.