1987 NISSAN PULSAR timing belt

25
ENGINE TUNE-UP
CAUTION: To prevent severe electrical shock, extreme care must be taken when
working on or near the electronic ignition system as dangerous high tension voltages
are produced in both the primary and secondary circuits. See the text fo\
r
precautionary notes.

1. TUNE-UP SPECIFICATIONS
Firing orde r................................................... 1 -3-4-2
Spark plugs:
Type .............................................NGK BPR 6ES
Gap ........................................................... 1.1 mm
Tightening torque...................................... 20 Nm
Ignition timing with diagnostic link
connector jumped........................... 10 deg BTDC
Idle speed (ECU controlled):
Manual transaxle 1.8 liter ............ 850 ± 50 rpm
Manual transaxle 1.6 liter............800 ± 50 rpm
Automatic transaxle
(Park or Neutral).......................... 825 ± 50 rpm
Drive belt deflection:
Alternator ........................................... 14-16 mm
Power steering pump ......................... 14-16 mm
Air conditioner compressor .................. 9-11 mm
NOTE: When performing an engine tune-
up, a/ways compare the above Specifications
with the emission control information label
inside the engine compartment.

2. TUNE-UP OPERATIONS
Special Equipment Required:
To Test Compression — Compression gauge
TO SERVICE AIR CLEANER
The air cleaner is equipped with a paper element.
The element should be regu larly inspected but should
not be cleaned in service.

The element should be renewed every 40 000 km.
This distance is only a guide for normal operating
conditions and should be reduced accordingly if the
vehicle is operating under ex tremely dusty conditions.

NOTE: Paper air cleaner elements should
not be washed in petrol or any other type of
cleaning solvent. If the element has been
washed in solvent or has become oil soaked,
it should be discarded and a new element
installed.

1.8 Liter Engine
(1) Release the clamp securing the air intake
hose to the throttle body and disconnect the throttle
cable from the support bracket. (2) Release the clips reta ining the upper air
cleaner housing to the lowe r air cleaner housing and
raise the upper housing while disconnecting the air
intake hose from the throttle body. Remove the air
cleaner element.

The air cleaner element should be renewed at 40 000
km intervals. 1.8 liter engine.
(3) Clean the inside of the air cleaner housing
using a damp rag to remove all traces of dust and
check the upper housing and air inlet hose for cracks
and air leaks. Renew if necessary. (4) Install a new air cleaner element to the lower
housing ensuring that the element is correctly seated
around the edges. (5) Install the upper housing and lock the clips,
securing it to the lower housing. Connect the air
intake hose to the throttle body and the throttle cable
to the support bracket. Tighten the hose clamp
securely. (6) Start the engine and check the air cleaner
assembly for air leaks.

36 Roadside Trouble Shooting


Check the engine oil for level and dilution on the dipstick.
turn creamy. The oil level will also have increased. If
the oil is emulsified, proceed to operation (5).

(2) Remove the fusible link that is positioned
third from the front of th e fusible link connection
block, located at the rear of the battery. Disconnect
the coil high tension lead from the coil. (3) Remove all of the spark plugs except one.
(4) Have an assistant operate the ignition switch
to rotate the engine and listen to the sound made by
the engine as it is being turned over. Move the spark
plug to a different cylinder and repeat the lest. By performing the same test on all cylinders, a
rough comparison can be made to determine if there
is any loss of compression in any cylinder. This will be
apparent by the different sound made by the engine as
it is being turned over.

Normally, if the compression is satisfactory the
cylinder with the spark plug installed will create a
resistance to the rotating engine.

However, if the compression is low in a particular
cylinder, the engine will tu rn over easily and smoothly
when that spark plug is in place.

(5) If the above checks show a loss of coolant
which is present in the engine oil or on the spark plug,
one or more of the following faults may be the cause:

Blown cylinder head gasket.
Cracked cylinder or cylinder head.
If the compression check showed any weak or
inconsistent compressions, in addition to the above
faults any of the following could also be the cause:

Broken piston{s)
Burnt or broken valve(s).
Provided the previous checks do not indicate an

View showing the location of the fusible links.
internal leakage of coolant, proceed with the follow-
ing:

(6) Remove the distributor cap and, with the aid
of an assistant operating th e starter motor, check that
the rotor arm rotates as the engine turns over. (7) Remove the camshaft hous ing top cover and.
again with an assistant operating the ignition switch,
check that all the valves open and close as the engine
turns over.
If the rotor arm or valves do not operate with
engine rotation, one of the following faults may be the
cause:

Rotor arm does not turn but valves operate:
Distributor drive shaft broken.

Rotor arm and valves do not operate: Broken
camshaft drive belt. Sheare d crankshaft timing gear
drive key. Sheared camshaft liming gear drive dowel.

Provided that all the previous checks have been
performed correctly and the operator is satisfied that
none of the components are at fault, all that remains
is for the ignition and valve timing to be checked. It
should be noted, however, that if loss of valve timing
proves to be the fault, th e cause of this occurrence
must be sought and rectified.

(8) In order to check the valve timing it will be
necessary to remove the distributor cap and the
camshaft housing top cover and turn the engine
clockwise via the crankshaft pulley until No. 1 piston
is at TDC on the compression stroke. In this position
the valves of No. 1 cylinder should be closed, the
valves of No. 4 should be rocking and the distributor
rotor should be pointing to the No. 1 high tension lead
segment in the distributor cap.

38 Engine
*Piston skirt to cylinder bore clearance:
1.6 liter .....................................0. 020-0.040 mm
1.8 liter .....................................0. 010-0.030 mm
Gudgeon pin length:
1.6 liter ...................................................... 53 mm
1.8 liter .................................................. 61.5 mm
Gudgeon pin diameter.................20.990-20.995 mm
Gudgeon pin clearance in piston:
1.6 liter .....................................0. 010-0.020 mm
1.8 liter ..................................0. 0055-0.0115 mm
Gudgeon pin offset in piston:
1.6 liter......... 0.35-0.65 mm towards thrust side
1.8 liter................... 0.8 mm towards thrust side
*Measured 9 mm from the bottom of the piston skirt
for 1.6 liter models and 6 mm from the bottom of the
piston skirt for 1.8 liter models.
PISTON RINGS
Rings per piston:
Compression .......................................................2
Oil contro l .......................................................... 1
End gap:
Compression ................................ 0.30-0.50 mm
Oil control —
1.6 liter ......................................... 0.33-1.10 mm
1.8 liter ......................................... 0.40-1.40 mm
CONNECTING RODS AND BEARINGS
Connecting rod side clearance............ 0.07-0.24 mm
Maximum connecting rod weight variation..8 grams
Crankpin bearing oil clearance ....... 0. 019-0.063 mm

CRANKSHAFT AND MAIN BEARINGS
Number of bearings .................................................. 5
End float taken at ...................... No. 3 main bearing
End float .......................................... 0.070-0.302 mm
Bend limit ...................................................0.03 mm
Main bearing oil clearance .............0. 015-0.040 mm
Main bearing journal diameter.. .57.982-57.995 mm
Crankpin diameter .......................48.971-48.987 mm

FLYWHEEL
Ring gear run out limit.................................. 0.3 mm
Clutch face regrind limit .............................. 0.3 mm
CAMSHAFT
Drive ...................................................... Toothed belt
End float .............................................. 0.04-0.14 mm
Bend limit ................................................... 0.03 mm
Bearings ...........................................Direct in housing
Journal diameter:
Standard —

No. 1 ..................................... 42. 455-42.470 mm
No. 2 ..................................... 42. 705-42.720 mm
No. 3 ..................................... 42.955-42.970 mm
No. 4 ..................................... 43.205-43.220 mm
No. 5 ..................................... 43.455-43.470 mm
Undersize —
No. 1 .....................................42.355-42.370 mm
No. 2 ......................................42.605-42.620 mm
No. 3 .....................................42.855-42.880 mm
No. 4 ......................................43.105-43.120 mm
No. 5 .....................................43. 355-43.370 mm
*An undersize camshaft can be identified by a violet
flash between the inlet and exhaust lobes of No. 2
cylinder.

Housing diameter;
Standard —

No. 1 .....................................42. 500-42.525 mm
No. 2 .....................................42.750-42.775 mm
No. 3 .....................................43.000-43.025 mm
No. 4 ......................................43.250-43.275 mm
No. 5 .....................................43.500-43.525 mm
*Undersize —
No. 1 .....................................42.400-42.425 mm
No. 2 .....................................42.650-42.675 mm
No. 3 .....................................42.900-42.925 mm
No. 4 ......................................43.150-43.175 mm
No. 5 .....................................43.400-43.425 mm
*An undersize camshaft housing can be identified by
a violet flash on the centre camshaft bearing support.

LUBRICATION
Oil pump type .......................................Involute gear
Filter type................................... Full flow disposable
Oil pressure at 4 000 rpm .....................480-620 kPa
Rotor assembly end float .................. 0.03-0. 010 mm
Rotor teeth backlash ......................... 0.010-0.20 mm
TORQUE WRENCH SETTINGS
*Cylinder head bolts:
Initial torque ............................................. 25 Nm
1st stage ......................................... + 60 degrees
2nd stage ........................................ + 60 degrees
3rd stage......................................... + 60 degrees
4th stage, engine at operating
temperature .............................. + 30-50 degrees
Exhaust manifold nuts .................................... 22 Nm
Exhaust manifold flange nuts ......................... 22 Nm
Inlet manifold nuts.......................................... 22 Nm
Throttle body to inlet manifold nuts ..............12 Nm
Camshaft liming gear bolt ...............................45 Nm
Camshaft retainin g plate bolts ......................... 7 Nm
Camshaft cover bolts......................................... 8 Nm
Thermostat cover bolts ....................................15 Nm
*Main bearing bolts..................60 Nm + 45 degrees
Connecting rod bearing
cap nuts ................................... 35 Nm + 45 degrees
* Crankshaft timing
gear bolt.................................. 145 Nm + 35 degrees
*Flywheel bolts
(microencapsulated) ................ 60 Nm + 30 degrees
*Drive plate bolts (microencapsulated)........... 60 Nm
Water pump bolts............................................ 25 Nm

Engine 41

DROP IN OIL PRESSURE
(1) Oil level low in the sump: Check and replen-
ish the oil to the full mark on the dipstick.
(2) Thin or diluted oil: Change to the correct oil
grade and rectify the source of dilution. (3) Oil pump relief valve stuck or spring broken;
Free up the relief valve or renew the broken relief
valve spring. (4) Excessive bearing clearance: Renew the bear-
ing shells or recondition the crankshaft journals as
necessary.
(5) Excessive wear of the oil pump components:
Renew or recondition the oil pump.
NOTE: If the vehicle is not equipped with an
oil pressure gauge re move the oil sender unit
and connect a pressure gauge into the oil
gallery. Check the oil pressure with the
engine cold and hot. If the oil pump or relief
valve are faulty. low pressure will be indi-
cated with the engine both hot and cold.
However, if the bearings are at fault a fairly
high oil pressure will be indicated when the
engine is cold, but a marked drop in pressure
will occur when the engine is hot.

ENGINE WILL NOT ROTATE
(1) Starter motor drive jammed: Remove the
starter motor. Check and renew the damaged drive
and/or flywheel ring gear.
(2) Engine overheated an d seized: Remove and
dismantle the engine. Check and renew any damaged
components. See the following note.
(3) Water in the cylinder due to a blown head
gasket or cracked cylinder block or head: Remove the
cylinder head. If the gasket is blown, check for
cylinder block and head distortion and reface if
necessary. Renew the cylinder head and/or cylinder
block if cracked.
(4) Broken crankshaft, connecting rod. piston
etc. due to overheating, fatigue etc: Remove and
dismantle the engine. Examine and renew any com-
ponents as necessary. (5) Valve head broken off due to overheating,
fatigue etc: Remove the cylinder head and check the
head, piston and cylinder bore for damage. Repair or
renew as necessary.
NOTE: Invariably when an engine seizes
because of overheating due to lack of oil
and/or water, damage is done to the bear-
ings, pistons etc. Although there may be
instances where an engine will start and run
after it has cooled down and the oil and
water have been replenished, it will usually
be found that oil consumption increases, oil
pressure decreases and the engine will be
noisier, depending on the degree of damage.

When a cylinder head gasket blows allow-
ing water into the cylinders, or compression
loss between the cylinders, it is essential to
check the gasket faces on the cylinder block
and head for distortion. Sufficient water can
enter a cylinder because of a blown head
gasket, cracked cylinder or head to prevent
an engine from rotating.

This is normally preceded by difficult
starting, misfiring, excessive steam from the
exhaust and loss of water from the radiator.

Frequent jamming of the starter motor
drive with the flywheel ring gear can be due
to a bent starter armature shaft or damaged
teeth on the drive and/or ring gear. With the
starter motor removed, the flywheel ring
gear teeth can be examined through the
starter motor mounting aperture. Renewal
of the ring gear requires removal of the
transaxle, clutch and flywheel on manual
transaxle models and the removal of the
transaxle and drive plate on automatic
transaxle models. To check for a bent arma-
ture shaft, rotate the shaft by hand while
holding the end in close proximity to a fixed
object.

2. DESCRIPTION
The 1.6 and 1.8 liter engines are basically identi-
cal in design.

Both engines share the same stroke. The 1.8 liter
engine has a larger bore thus giving it increased
capacity.

The engine is a four cylinder, inline, overhead
camshaft design transversely mounted in the front of
the vehicle.

The camshaft runs in five integral support bear-
ings in the camshaft housing which in turn is mounted
directly on to the cylinder head and retained by the
cylinder head bolts.

Camshaft end float is controlled by a retaining
plate engaged in a groove machined in the rear
camshaft journal. The camshaft is driven by the
crankshaft timing gear vi a a reinforced rubber belt.

The aluminum cross flow cylinder head houses
the tappets, rocker arms a nd valve assemblies. An oil
pressure relief valve is installed to the cylinder head to
maintain oil pressure to the hydraulic tappets at a
predetermined setting.

The exhaust valve springs are equipped with
rotators mounted below the valve springs which rotate
the exhaust valve assemblies. The rocker arms pivot
on hydraulic tappet assemblies and locate in notched
lash pads mounted on the valve stems. The camshaft
lobes bear directly onto the rocker arms and due to
the characteristics of the hydraulic tappet assemblies,
no provision is made for tappet clearance adjustment.

46 Engine
(1) Ensure that all carbon and old gasket mate-
rial 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) Adjust the throttle cabl e as described in the
Fuel and Engine Management section and the kick-
down cable as described in the Automatic Transaxle
section.
(5) Start the engine and check for air, fuel and
water leaks.
EXHAUST MANIFOLD

To Remove and Install
(1) Bring the engine to operating temperature
and remove the oxygen sensor.
(2) Disconnect the negative battery terminal.
(3) On 1.6 liter models, remove the air cleaner
nuts, disconnect the vacuum hose and withdraw the
air cleaner from the vehicle. (4) Remove the front exhaust pipe flange mount-
ing nuts and separate the exhaust pipe from the
manifold. (5) Remove the heat shield retaining bolts and
withdraw the heat shield from the exhaust manifold. (6) Remove the exhaust manifold to cylinder
head retaining nuts and remove the manifold from the
engine. Discard the manifold gasket. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Ensure that all carbon is cleaned from the
manifold and cylinder head mating surfaces. (2) Check the face of the manifold for distortion
using a straight edge and feeler gauges. (3) Use new gaskets on assembly.
(4) Tighten the exhaust manifold retaining nuts
to the specified torque in the sequence shown in the
illustration. (5) Install the oxygen sensor. Refer to the Fuel
and Engine Management section. (6) Coat the threads of the front exhaust pipe to
manifold retaining nuts with an anti-seize solution
and tighten the nuts to the specified torque.
5. CAMSHAFT DRIVE BELT
Special Equipment Required:
To Adjust — Drive belt adjusting tool
TO REMOVE
(1) Disconnect the negative battery terminal.
(2) Raise the front of the vehicle, support it on
chassis stands and remove the right hand front wheel.
Refer to the Wheels and Tires section. (3) Remove the fasteners securing the engine
splash guard to the right hand front inner mudguard
and remove the splash guard. (4) Loosen the alternator adjusting bolt and if
equipped, the power steering and air conditioning
adjusting bolts. Remove the drive belt(s).


View of the exhaust manifold and components showing
the correct tightening sequence.

View of the 1.8 liter engine with the upper timing belt
cover removed showing the camshaft gear timing
marks. Inset shows the crankshaft pulley timing
marks.

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.

48 Engine

TO INSTAL
(1) Check that the camshaft and crankshaft
timing gears have not been moved and that the timing
marks are still aligned. It will be necessary to tempo-
rarily install the crankshaft pulley to check that the
timing marks are still aligned. (2) Install the drive belt to the crankshaft timing
gear around the water pump gear and onto the
camshaft timing gear.
NOTE: If the original drive belt is being
installed, ensure that the arrow marked on
the belt prior to removal is pointing in the
direction of rotation.

(3) Use the adjusting tool to turn the water
pump assembly sufficiently to engage the water pump
pulley with the drive belt. (4) Install the inner cover lower retaining bolt.
(5) Ensure that the drive be lt is correctly meshed
with the teeth of the camshaft, crankshaft and water
pump gears. Install the crankshaft pulley and tighten
the bolts to Specifications. (6) Adjust the drive belt as described under the
following heading.
(7) Install the drive belt outer cover and fasten
the retaining clips. (8) Install and adjust the alternator and if
equipped, the power steeri ng and air conditioning
drive belts as desc ribed in the Engine Tune-up section.
TO ADJUST

(1) Remove the alternator drive belt and if
equipped, the power steering and air conditioning
drive belts. (2) Release the clips securing the camshaft drive
belt outer cover to the inner cover and remove the
outer cover. (3) Turn the engine in the direction of rotation
until the timing marks on the camshaft and the inner
cover are aligned. (4) Loosen the water pump retaining bolts and
using the adjusting tool, rotate the water pump
housing to gain the required belt tension. The belt is
correctly tensioned when it can be grasped between
the thumb and forefinger midway between the cam-
shaft timing gear and the water pump gear and turned
ninety degrees from i t s operating position.
After the belt has been tensioned, tighten the
water pump retaining bolts to the specified torque.

NOTE: Over tensioning of the drive belt will
result in noisy operation and premature
wear of the belt.

(6) Install the outer drive belt cover.
(7) Install and adjust the alternator, and if
equipped, the power steering and air conditioning
drive belts as desc ribed in the Engine Tune-up section. 6. CAMSHAFT. ROCKER ARMS AND TAPPETS

Special Equipment Required:
To Check Camshaft — Dial gauge, Vee blocks and
micrometers
To Install — Drive belt adjusting tool
It is recommended that a new cylinder head
gasket is installed and the cylinder head bolts renewed
when the camshaft housing is removed.

TO REMOVE
(1) Disconnect the negative battery terminal.
Remove the nuts securing the earth wires to the
cylinder head bolts and remove the earth wires.
(2) On 1.6 liter models, remove the air cleaner
wingnuts and withdraw the air cleaner.
(3) Disconnect the engine breather hoses from
the camshaft housing and the camshaft housing top
cover. (4) Remove the camshaft housing top cover
retaining bolts and remove the top cover. Discard the
gasket.
(5) Remove the camshaft dr ive belt as described
under the previous heading. (6) Using an open ended spanner, hold the
camshaft between the inle t and exhaust lobes of
number four cylinder and remove the camshaft timing
gear retaining bolt and the camshaft timing gear.
(7) Remove the distributor, distributor cap and
high tension leads. If necessary refer to the Fuel and
Engine Management section. (8) Check the camshaft end float before remov-
ing the camshaft from the engine. Mount a dial gauge
to the cylinder block with the plunger bearing on the
distributor drive end of the camshaft. (9) Lever the camshaft towards the dial gauge
and zero the gauge. Move the camshaft in the opposite
direction away from the dial gauge and note the
reading obtained. Check this measurement against
Specifications.

Checking the camshaft end float.

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