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1.8L DOHC ENGINE MECHANICAL 1C2 – 17
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53. Remove the generator–to–intake manifold support
bracket bolts at the cylinder head and the intake
manifold.
54. Remove the generator support bracket.
55. Remove the intake manifold–to–generator strap
bracket bolt and loosen the bolt on the generator.
56. Move the strap clear of the intake manifold.
57. Remove the charcoal canister purge (CCP) and
EGR solenoid bracket bolt and move the bracket
clear.
58. Disconnect the throttle cable at the throttle body
and the intake manifold.
59. Loosen all of the cylinder head bolts gradually and
in the sequence shown.
60. Remove the cylinder head bolts.
61. Remove the cylinder head with the intake manifold
and the exhaust manifold attached.
Notice : Prevent any engine oil or coolant from entering
the cylinders when removing the cylinder head.
62. Remove the cylinder head gasket.
Cleaning Procedure
1. Clean the gasket surfaces of the cylinder head and
the engine block.
2. Make sure the gasket surfaces of the cylinder head
and the engine block are free of nicks and heavy
scratches.
3. Clean the cylinder head bolts.
4. Inspect the cylinder head for warpage. Refer to
”Cylinder Head and Valve Train Components” in
this section.
Installation Procedure
1. Install the cylinder head gasket.
2. Install the cylinder head with the intake manifold
and the exhaust manifold attached.
3. Install the cylinder head bolts.
4. Tighten the cylinder head bolts gradually and in the
sequence shown.
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Tighten
Tighten the cylinder head bolts to 25 NSm (18 lb–ft)
and turn the bolts another 3 turns of 90 degrees using
the angular torque gauge KM–470–B.
5. Connect the throttle cable at the throttle body and
the intake manifold.
6. Install the generator–to–intake manifold support
bracket.
7. Install the intake generator–to–manifold support
bracket bolts.
Tighten
Tighten the generator–to–intake manifold support
bracket bolts to the intake manifold to 37 NSm (27 lb–
ft).
8. Install the intake manifold support bracket bolt to
the generator.
Tighten
Tighten the generator–to–intake manifold support
bracket bolt at the generator to 22 NSm (16 lb–ft).
9. Connect the surge tank coolant hose at the throttle
body.
10. Connect the coolant hose to the rear cylinder head
and ignition coil EGR bracket.
11. Connect the fuel feed line at the fuel rail.
12. Connect the fuel return line at the fuel rail.
13. Connect all of the necessary vacuum hoses.
14. Install the fuel rail assembly. Refer to Section 1F,
Engine Controls.
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1.8L DOHC ENGINE MECHANICAL 1C2 – 19
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15. Install the exhaust flex pipe retaining nuts at the
exhaust manifold studs.
Tighten
Tighten the exhaust flex pipe–to–exhaust manifold
retaining nuts to 35 NSm (26 lb–ft).
16. Install the rear timing belt cover.
17. Install the rear timing belt cover bolts.
Tighten
Tighten the rear timing belt cover bolts to 7 NSm (62
lb–in).
18. Install the engine mount and the retaining bolts.
Tighten
Tighten the engine mount retaining bolts to 45 NSm
(33 lb–ft).
19. Install the timing belt automatic tensioner.
20. Install the timing belt automatic tensioner bolt.
Tighten
Tighten the timing belt automatic tensioner bolts to 25
NSm (18 lb–ft).
21. Install the timing belt idler pulleys.
22. Install the timing belt idler pulley bolt and nut.
Tighten
Tighten the timing belt idler pulley bolt to 25 NSm (18
lb–ft).
23. Install the camshaft gears with the timing marks at
the front.
24. Insert the guide pin of the intake camshaft into the
”IN” bore.
25. Insert the guide pin of the exhaust camshaft into
the ”EX” bore.
26. Install the camshaft gears by counterholding on the
hex of the camshaft with an open–ended wrench.
27. Install the camshaft gear with a new bolt to the
camshaft.
Tighten
Tighten the intake camshaft gear bolt to 50 NSm (37
lb–ft) turn the bolt another 60 degrees and 15 degrees
using the angular torque gauge.
28. While holding the exhaust camshaft firmly in place,
install the exhaust camshaft gear bolt.
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Tighten
Tighten the exhaust camshaft gear bolt to 50 NSm (37
lb–ft) turn the bolt another 60 degrees and 15 degrees
using the angular torque gauge.
29. Apply a small amount of gasket sealant to the cor-
ners of the front camshaft caps and to the top of
the rear camshaft cover–to–cylinder head seal.
30. Install the camshaft cover and the camshaft cover
gasket.
31. Install the camshaft cover washers.
32. Install the camshaft cover bolts.
Tighten
Tighten the camshaft cover bolts to 8 NSm (71 lb–in).
33. Connect the ignition wires to the spark plugs.
34. Install the spark plug cover.
35. Install the spark plug cover bolts.
Tighten
Tighten the spark plug cover bolts to 8 NSm (71 lb–in).
36. Connect the breather tube to the camshaft cover.
37. Align the timing marks on the camshaft gears to the
notches on the camshaft cover, using the intake
gear mark for the intake gear and the exhaust gear
mark for the exhaust gear.
38. Align the mark on the crankshaft gear with the
notch at the bottom of the rear timing belt cover.
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39. Install the timing belt.
40. Check and adjust the timing belt tension. Refer to
”Timing Belt Check and Adjust” in this section.
41. Install the front timing belt cover.
42. Install the front timing belt cover bolts.
Tighten
Tighten the front timing belt cover bolts to 6 NSm (53
lb–in).
43. Install the crankshaft pulley.
44. Install the crankshaft pulley bolts.
Tighten
Tighten the crankshaft pulley bolts to 12 NSm (106 lb–
in).
45. Install the right engine mount bracket and retaining
bolts.
Tighten
Tighten the engine mount bracket retaining bolts to 55
NSm (41 lb–ft).
46. Remove the engine assembly lift support
J–28467–B.
47. Install the serpentine accessory drive belt. Refer to
Section 6B, Power Steering Pump.
48. Connect the upper radiator hose to the thermostat
housing.
49. Install the right front wheel well splash shield.
50. Install the right front wheel. Refer to Section 2E,
Tires and Wheels.
51. Install the air cleaner housing.
52. Install the air cleaner housing bolts.
Tighten
Tighten the air cleaner housing bolts to 10 NSm (89 lb–
in).
53. Connect the air cleaner outlet hose to the throttle
body.
54. Connect the breather tube to the camshaft cover.
55. Connect the MAT sensor connector.
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56. Connect the CTS connector.
57. Connect the engine CTS connector.
58. Connect the IAC valve connector.
59. Connect the TPS connector.
60. Install the CCP and the EGR solenoid bracket bolt.
Tighten
Tighten the charcoal canister purge and exhaust gas
recirculation solenoid bracket bolt to 5 NSm (44 lb–in).
61. Connect the DIS coil connector.
62. Connect the O2 sensor connector, if equipped.
63. Connect the ECM ground terminal.
64. Install the fuel pump fuse.
65. Connect the negative battery ground cable.
66. Refill the engine cooling system. Refer to Section
1D, Engine Cooling.
CAMSHAFTS
Removal Procedure
1. Remove the timing belt. Refer to ”Timing Belt” in
this section.
2. Disconnect the breather tube at the camshaft cov-
er.
3. Disconnect the engine ventilation hose at the cam-
shaft cover.
4. Remove the spark plug cover bolts.
5. Remove the spark plug cover.
6. Disconnect the ignition wires from the spark plugs.
7. Remove the camshaft cover bolts.
8. Remove the camshaft cover washers.
9. Remove the camshaft cover and the camshaft cov-
er gasket.
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
10. While holding the intake camshaft firmly in place,
remove the intake camshaft gear bolt.
11. Remove the intake camshaft gear.
12. While holding the exhaust camshaft firmly in place,
remove the exhaust camshaft gear bolt.
13. Remove the exhaust camshaft gear.
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1.8L DOHC ENGINE MECHANICAL 1C2 – 23
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14. Loosen the camshaft bearing cap bolts in stages of
one–half to one turn.
15. Remove the camshaft bearing cap bolts from the
cylinder head.
16. Remove the camshafts.
17. Remove the seal ring from the camshafts.
Important : The camshaft must detach evenly from the
bearing seats in the front guide bearing.
18. Check the camshaft and bearing seats for wear and
replace them if necessary.
Installation Procedure
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
1. Lubricate the camshaft journals and the camshaft
caps with engine oil.
2. Install the intake camshaft.
3. Install the intake camshaft caps in their original
positions.
4. Install the intake camshaft cap bolts.
5. Install the exhaust camshaft.
6. Install the exhaust camshaft caps in their original
positions.
7. Install the exhaust camshaft cap bolts.
8. Tighten the camshaft cap bolts gradually and in the
sequence shown for each camshaft cap.
Tighten
Tighten the camshaft bearing cap bolts to 8 NSm (71
lb–in).
9. Measure the intake camshaft end play and the ex-
haust camshaft end play. Refer to ”Engine Specifi-
cations” in this section.
10. Install the intake camshaft gear.
11. While holding the intake camshaft firmly in place,
install the intake camshaft gear bolt.
Tighten
Tighten the intake camshaft gear bolt to 50 NSm (37
lb–ft) plus 60 degrees and 15 degrees using the angu-
lar torque gauge KM–470–B.
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12. Install the exhaust camshaft gear.
13. While holding the exhaust camshaft firmly in place,
install the exhaust camshaft gear bolt.
Tighten
Tighten the exhaust camshaft gear bolt to 50 NSm (37
lb–ft) plus 60 degrees and 15 degrees using the angu-
lar torque gauge KM–470–B.
14. Install the camshaft cover and the camshaft cover
gasket.
15. Install the camshaft cover washers.
16. Install the camshaft cover bolts.
Tighten
Tighten the camshaft cover bolts to 8 NSm (71 lb–in).
17. Connect the ignition wires to the spark plugs.
18. Install the spark plug cover.
19. Install the spark plug cover bolts.
Tighten
Tighten the spark plug cover bolts to 8 NSm (71 lb–in).
20. Connect the breather tube to the camshaft cover.
21. Connect the engine ventilation hose to the cam-
shaft cover.
22. Install the timing belt. Refer to ”Timing Belt” in this
section.
TIMING BELT CHECK AND ADJUST
(Left–Hand Drive Shown, Right–Hand Drive
Similar)
Adjustment Procedure
1. Disconnect the negative battery cable.
2. Disconnect the manifold air temperature (MAT)
sensor connector.
3. Remove the air cleaner outlet hose from the throttle
body.
4. Remove the breather tube from the camshaft cover.