5

Section 2 Drive Belt Replacement

1. Disconnect all engine pipe hose and wire joint. Remove engine assembly from the engine

compartment, jack up the body, take out the engine assembly slowly (See Provision 20, Section

Two, Chapter Two for detailed information)

2. Remove generator V-belt  See (Figure 5)

3. Remove No. 1 V-belt A/C compressor to crankshaft pulley

4. Remove water pump belt  See (Figure 6)

5. Install water pump V-belt

6. Adjust V-belt of steering assisting pump

(a) Adjust power steering belt tension, tighten bolt B.

(b) Tighten bolt A.

       Torque : 39N. m

7. Install V-belt A/C compressor No. 1 to crankshaft pulley

8. Adjust V-belt A/C compressor No. 1 to crankshaft pulley

(a)  Adjust A/C belt tension by tightening bolt B.

(b)  Tighten nut A.

Torque : 39N. m

9. Install Generator V-belt  See (Figure 7)

10. Adjust Generator V-belt.

Tighten bolt A and then bolt B.

Torque: Bolt A 18N. m Bolt B 58N. m

11. Check driving belt for distortion and tension

Figure 7

Figure 6

Figure 5 

6

Section 3 Valve Clearance Adjustment

1. Remove right camshaft timing gear

2. Remove ignition coil and high voltage cable

3. Remove cylinder head cover sub-assembly  See (Figure 8)

(a) Disconnect generator wire joint..

(b) Disconnect generator circuit.

(c) Disconnect oil pressure switch connector.

(d) Disconnect A/C compressor switch connector.

(e) Open the wire harness clip.

(f) Remove wire harness from cylinder head cover.

(g) Separate 2 ventilation hoses from cylinder head cover.

(h) Remove 4 screw nuts, 4 oil seal gaskets, cylinder head and gasket.

4. Adjust piston of Cylinder 1 to the compression position

(a) Turn crankshaft pulley, align notch to timing mark "0" on Cylinder 1. See (Figure 9).

(b) Align mark "K" on camshaft timing pulley to the timing mark on bearing cap. See (Figure 10) Crank 360°

if it is not aligned.

5. Check valve clearance (cool). See (Table 5)

(a) Turn the crankshaft pulley for 360°. Align notch to timing mark "0" on timing belt cover No. 1.

(b) Only check the valve as shown in the figure. Valve clearance measurement. See (Figure 11).

   Figure 8

Figure 10

Intake Valve mm

Exhaust Valve mm

MR479Q

   0.20 ± 0.05

  0.30 ± 0.05

MR479QA

0.20 ± 0.05

0.30 ± 0.05

MR481QA

   0.20 ± 0.05

0.30 ± 0.05

Table 5

Figure 9 

7

6. Adjust intake valve clearance

(a) Detach intake camshaft

Notice:

Because the camshaft end play is quite small, keep camshaft horizontal when removing it. If not, cylinder

head may be partially damaged by the thrust force£¬it may stuck or damage camshaft when turning crankshaft.

Take the following steps to avoid the damage:

(1) Turn the pulley to access the hole on the camshaft drive gear where the counter gear is installed. See

(Figure 12).

Hint:

The above condition allows the cylinders No. 1 and No. 3 of the intake camshaft to push up the valve tappet.

(2) Remove bolt and bearing cap No. 1.

(3) Install camshaft counter gear to drive gear with service bolt. See (Figure 13).

(4) Uniformly loose and remove 8 bearing cap bolts in several passes as

shown in the figure. See (Figure 14).

(5) Remove 4 bearing caps and camshafts.

Figure 11

Figure 14

Figure 12 

 Figure 13

8

Notice:

Due to the small end play on camshaft, the cylinder head may be damaged by the thrust force when removing

it, it may stuck or damage camshaft. Take the following steps to avoid damage:

 (1) Turn the crankshaft pulley to make exhaust camshaft dowel pin is a bit higher than the cylinder head. See

(Figure 15).

 (2) Align the matchmark on each gear to engage intake camshaft gear and exhaust camshaft gear. See

(Figure 16).

 (3) When the gears are engaged, install the intake camshaft bearing onto bearing journal.

Hint:

The intake camshaft lobe of cylinder 1 and 3 can jack up their own valve tappet.

(5) Install 4 bearing caps to the right position.

(6) Apply a light layer of engine oil on the thread and under the head of bearing cap bolts.

(7) Uniformly install and tighten 8 bearing cap bolts in several times, in the sequence shown in the figure.

Torque: 13N. m

(8) Remove service screw.

(9) Install the bearing cap No. 1. in the direction of the forward arrow mark.

(10)Apply a light layer of engine oil on the thread and under the head of bearing cap bolts.

(11)Alternatively tighten and install 2 bearing bolts.

Torque: 13N. m

7. Adjust exhaust valve clearance. See (Figure 17)

Remove adjust gasket.

 (1) Crank to keep the camshaft head upward.

 (2) Face valve tappet nick to vehicle front.

 (3) Press valve tappet, put special tool between camshaft and valve tappet.

Hint:

z

Lean the end with mark "9" into the position in (Figure 18).

Figure 15

Install Mark

Timing Mark

March Mark

Cam Lobe

Upward

Nick

Front

Figure 17

Figure 18

Figure 16