25

 (b) Remove the counter gear of the camshaft.

(1) Clamp the camshaft's hexagon on the vise.

(2) Turn the counter gear cloclwise, Remove the service bolt.

(3) Remove the snap ring with a circlip pliers. See (Figure 57).

(4) Remove waved gasket, camshaft counter gear and the camshaft gear spring. See (Figure 58)

24. Remove and install spark plug hole gasket. See Provision 15 and 16, Section 3 Timing Belt

Replacement for detailed information. See (Figure 44, 45).

Figure 57

25. Install camshaft

(a) Install exhaust camshaft and turn camshaft counterclockwise to make the dowel pin cross the vertical

line a little. See (Figure 59).

(b) Apply grease to a new oil seal lip and install it into the oil seal. See (Figure 60).

Figure 59 

(c) Install camshaft counter gear.

 (1)  Clamp the camshaft's hexagon head with a vise.

 (2) Install camshaft gear spring, camshaft counter gear and waved washer. (Figure 61).

Hint: Align the pin on the gear to the spring end of the counter gear.

 (3) Install the snap ring with a circlip plier.

 (4) Turn the counter gear clockwise with the special tool. Align the

holes on the camshaft drive gear. Install the service bolt.

Figrue 61

Rotate

Figure 58

Figure 60

26

(d)  Install intake camshaft.

 (1) Make the exhaust camshaft dowel pin a bit higher than the top of the cylinder head.

 (2) Apply grease to camshaft's contact surface.

 (3)  Install intake camshaft gear to exhaust camshaft gear , 

Align the matchmarks on each gear. See (Figure 62).

 (4) Check the timing marks on the camshaft gear for 

alignment.See (Figure 63).

Hint: Matchmark is on the top.

26. Adjust valve clearance

27. Install camshaft timing pulley

Turn the camshaft's hexagon head. Tighten the timing pulley bolt. See (Figure 64).

Torque: 59N. M

Figure 63

Figure 65

28. Install the timing belt

(a) Align the marks on timing belt and the one on camshaft timing pulley.

(b)  Install timing belt. Check tension force between the crankshaft timing pulleys. See (Figure 65).

29. Check valve timing

(a) Loose idler bolt.

(b) Turn crankshaft from TDC clockwise for 2 cycles.

(c) Check and align each pully to the timing mark as shown in Figure 66. Remove timing belt and reinstall it

if not.

30. Install crankshaft gear or pulley cover sub-assembly

Torque: 9.3N. m

Figure 62

Install Mark

Timing Mark

Install Mark

Install Mark

Timing Mark

5-6mm

 Figure 64

 Figure 66

27

31. Install timing belt cover

Torque: 9.3N. m

32. Install generator assembly

33. Install right engine mounting bracket. See (Figure 67)

34. Install cylinder head cover sub-assembly

(a) Install 2 ventilation PCV hoses to the cylinder head cover.

(b) Connect the generator wire.

(c) Install the wire clip.

(d) Connect A/C compressor switch connector.

35. Install water pump pulley

36. Install power steering pump V-belt

37. Install A/C compressor to crankshaft pulleyV-belt

38. Install generator V-belt

39. Install left & right rear mounting bracket of engine.

40. Install ignition coil and high voltage cable

41. Hoist the engine back into the compartment

42. Install propeller shaft

43. Install air filter assembly with hose

44. Install oil pipe and water hoses

45. Install left and right front tires.

46. Check engine oil for leakage

47. Install all the wire harnesses and the cables on the engine connected to car body

Figure 67

28

Section 5  Cylinder Head Gasket Replacement

Component 1

Figure 68

Vane Pump Assembly V/ Power Steering

Throttle Body Assembly

Gasket

Dipstick

Inlet Pipe

Gasket

Wire Harness

O-Ring

Timing Chain Or Timing Belt Cover No. 2

Crankshaft Or Pulley Cover Sub-Assembly

Fan Pulley

Fuel Delivery Pipe No.1