FE DOHCENGINE 1O-1

G R O U P1 O

FE DOHCENGINE

CONTENTS
Assembly. 10-60
AuxiliaryPartsTorque 10-78
CamshattPulleys. . 10-18
Camshatts 10-22
CylinderBlock.. 10-42
CylinderBlockTorque. . .. 10-66
CylinderHead 10-29
CylinderHeadCover. . . 10-20
Diagnosis . 10-3
TimingBelt 10-5
Disassembly 10-38
Engine. 10-2
EngineHanger. 10-81
Installation. 10-82
Removal 10-33
GeneralDescription ...... 10-2
Inspection andRepair 10-45
Valveand ValveGuide '|0-48
Replacement of ValveGuide. 10-49
ValveSeat. 10-50
ValveSpnng 10-51
CylinderHead. 10-46
Intakeand ExhaustManifold 10-24
IntakeManifold. 10-25
ExhaustManitold 10-27
On-VehicleService.. 10-6
Camshafts. 10-22
CamshaftPulleys.. '10-18
Specifications 10-88
Fastener'l'ightening Specitication. 10-88
GeneralSpecifications .... 10-89
TimingBelt. 10-12
'f
i m i n gB e l T
t o r q u e. . . . . . 10-75
Tune-UpProcedure 10-6
A i rC l e a n eErl e m e n. .t . . . . 10-6
Battery. . 10-6
Compression. 10-11
DriveBelts. 10-8
EngineCoolant. 10-8
EngineOil 10-7
High-TensionLead.... 10-10
ldleSpeed.. 10-10
lgnitionTiming 10-10
SparkPlug 10-6
1O-2 FE DOHCENGINE

GENERAL
DESCRIPTION
FEDOHCENGINE t 1 . " ' :

The 2.0LFE DOHCfuel-injected engineis a four-cylinder dualoverheadcamshaftdesignwitha g.2:1compression

ratio.Thetuel-iniected
engineincorporates a cast ironblocldaluminum headcombination that providessuperiorheat
conductivityandheatresistance. The combustion chamberof the cylinderheadcontainsfourvalves(twointakeand
two exhaust)percylinder.Theenginehasa SequentialMultiportFuelInjection(SFl)systemand useshydraulic lash
adjuslers(HLAs)to reduceenginenoise.
The cast-ironcylinderblockhasfive mainbearingsupportsfor the crankshaft. Thefrontand rearcrankshaft sealsare
one piece.Thelargerodendsusea replaceable bearinginsert.Grooveson the connecting rodand rodcapprovide
lubrication
to thecylinderwallsand coolthe pistons.In addition,pistoncoolingjets (threaded intothe mainoil galleyof
the cylinderblock)provideadditional coolingto the pistonsandadditionallubricationto the pistonpinswhenever oii
pressurerisesabove25 psi.
The lubricationsystemis a wet sumptypethatdistributes pressurizedoil throughouttheenginefromthe oil pan.Theoil
trav€lstromtheoil pumpthroughout the engine,includingthe crankshaft mainbearings, the connectingrodbearings
and the camshaftbearicgs.
The enginecoolingsystemincludesa forward-mounted waterpump,a thermostatanda thermostaticallyoperated
coolingfan.Thethermostat controlscoolanttemperature, and is locatedwithinthe wateroutlethousingat thefrontof
the cylinderblock.The coolingfan is mountedon lhe frontsideol the engineat the radiator, and is controlled
by a
bimetaldevice.

1. Oil LevelGauge EngineHanger 1 1 . Oil Filter

Thermo-Modulated FanBracket 7. Generator 12. Oil Cooler
ExhaustManifoldHeatShield 8. GeneratorStraoand Bracket 1 3 . Oil PressureSwitch
4. ExhaustManilold 9. IntakeManifold
Assembly
5. CoolantInletPip€and BypassPipe 10. IntakeSuooortBracket
 FE DOHCENGINE 1O-3

DIAGNOSIS
FE DOHCENGINE
Problem PossibleCause Action
Enginewill not Battery,startingsystemor otherelectricalproblems Aeler to StaftingSystem,
crank Section31, Charging
System,Section32, or
the Electrical
Troubleshooting Manual
Liquidin combustion chamber Removewithsuction gun,
then crankengineover
withsparkplugs
removed
Seizedengine Repair
Enginecranks Malfunction of luel system Reier lo Fuel System,
normally,but does Sectioo22
not start Malfunction of ignitionsystem Relet 10 lgnition System,
Section30
lmpropervalveclearance CheckHLAS
Restrictedexhaustsystem Retet to ExhaustSystem,
Section20
Timingbeltand/orrelatedparts Inspecttimingbeltand
relatedparts;replaceif
necessary
Lowcompression due to: stuckor burnedvalves;worn Performa compression
piston,pistonringor cylinder; failedcylinderheadgasket test, as outlinedin this
section;repairengineas
necessary
Camshaftworn Replace
Pooridling Malfunction of fuel system Refer lo Fuel System,
Section22
Malfunction of emissionsystem Retet to EmissionControl
Systen, Section21
Malfunction of ignitionsystem Relet lo lgnition System,
Seclion30
lmpropervalveclearance CheckHLAS
Unevencylinder compression Performa compression
test,as outlined in this
seciion;repairengineas
necessary
Poorvalve-to-valve seatcontact Repairor replace
Brokenvalvespring Repair
Failedcylinderheadgasket Replace
Whitesmokeout of Usuallycausedby watervapo( whichis a normalby-product Nonerequired
exhaust ot combustion on cold days
Excessive whitesmokewithenginewarmedup couldbe Repairor replace
causedby a failedcylinderheador intakegasket.Couldalso
be a crackedblock,cvlinderheador intakemanifold
Black smoke out of Malfunctionof fuel system Retet to Fuel System,
exhaust Section22
Malfunctionof emissionsystem Retet to EmissionControl
System,Section21
Blue smoke out ot Usuallycausedby oil burningin thecombustion chambers Replace
exhaust from:wornrings,wornvalveguides,wornvalvesealsor
tailedcylinderhead gasket
Valvetrain noise Wornvalveguides Repair
1O-4 FE DOHCENGINE

Problem PossibleCause Action

Valvetrain noise Lowoil pressure Refet to Lubrication
Syslem,Section11
lmpropervalveclearance CheckHLAS
Brokenvalvespring Replace
Stickingvalves Freevalves
Camshaftwornor faulty Replace
Insufficient power Insufficientcompression causedby:
1. improper valveclearance CheckHLAS
2. leakagelrom valveseat Repairor replace
3. seizedvalvestem Replace
4. weakor brokenvalvesprin€ Replace
5. tailedcylinderheadgasket Replace
6. crackedor distortedcylinderhead Repairor replace
7. sticking,damagedor wom pistonring Replace
8. crackedor wornpiston Replace
Malfunctionof fuel system Refer to Fuel System,
Section22
Slippingclutch Refet lo Clutch,Section40
Draggingbrakes Referto ErakeSystem,
Section52
Wrongtire size Retetto Wheelsand Tires,
Section53
Restnctedexhaustsystem Reterlo ExhaustSystem,
Section20
Abnormal lmpropervalveclearance CheckHLAS
combustion Stickingor bumedvalve Replace
Weakor brokenvalvespring Replace
Carbonaccumulationin combustionchamber Eliminatecarbon
Engineknocks Looseor wom accessorydrivebelVtensioner Checkbeltsandtensioners
when hot and at idle Replaceit necessary
Replace
A'/Ccompressoror generatorb€aring Installproperoil viscosity
lmproperoil viscosity for expected
temperatures
lnstallnew piston,pin
Excessivepistonpin clearance and/orconnecting rod
Checkand replacerods.il
Connectingrod alignment necessary
Honeand fit newpistonsif
pistonto boreclearance
Insufficient required
Replace
Faultytimingbelttensioner
or guide Tightenor replaceif
Loosedamperpulley necessary

Slight noise at idle, Valvespringclickingon cap,off squareor broken Repairor replace

becomeslouder as Excessivestemto guideclearance Repair
engine speed is
increased Excessivevalveseat runout Bepair
Engineknocks Excessiveoistonto wall clearance Replacepistons
when cold Looseor brokendamperpulley Tightenor replace
Knock increases Excessivepistonto boreclearance Replacepiston
with torque Bentconnectingrod Replace
 FE DOHCENGINE 10.5

Problem PossibleCause Action

Enginehas heavy Brokendamperpulley Replace
knock when hol and Accessorybeltstoo tight or damaged Adjustor replacebelt
torque is applied Belttensionerdamaged Replace
Flywheelcrackedor looseclutchplate Replaceflywheelor clutch
plate
Excessivemainbearingclearance Repair
Excessiverodbearingclearance Bepair
Enginehas light lmpropertiming Checktiming
knock when hot and Pistonpin and/orconnectingrod Replacepistonpin and/or
under light load roo
conditions Poorqualitytuel Use recommended or
highergradefuel
Exhaustleakat manifold Tightenboltsand/or
replaceexhaustmanitold
gasketsif necessary
Excessiverodbearingclearance Repair
Engineknockson lmproperoil viscosity Installproperoil viscosity
initial starl up and tor expected
knock lasts only a temperatures
lew seconds

TIMINGBELT
Problem PossibleCause Action
Tooth is broken or Camshaft
iamming Inspectcamshattbyrenroving
cracked cylinderheadcover
Bepairor replaceit necessary
Backsurtaceis jamming
Tensioner Removetensionerand
crackedand/or inspect
urorn Replaceii necessary
Overheating
engine Inspectcoolingsystem
Retet to EngineCooling
System,Section12
Intederence
withtimingbeltcover Removetimingbeltcover
and inspect
Replaceif necessary
Side surfaceis worn lmproperinstallation
of limingbelt Removetimingbeltand
and/ortrayed reinstall
ot timingbelt guideplate
Malfunction Removetimingbeltand
inspectguideplate
Teethare worn Poorbeltcoversealing Removetimingbeltcover
and inspect
Replaceif necessary
Coolantleakageat waterpump Inspectwaterpump
Replaceif necessary
Camshaft properly
nottunctioning Inspectcamshaftby
removingthe cylinder
headcover
Repairor replacerf necessry
Removetensioner spring
Excessivebelttension and inspect
Replaceif necessary
Oil or coolant is Pooroil sealing InsDectfrontoil seals
stuck to belt Replaceif necessary
Coolantleakageat waterpump Inspectwaterpump
Replaceif necessary
Poor beltcoversealing R€movetimingbeltcover
and inspect
Replaceif necessary
10.6 FE DOHCENGINE

ON.VEHICLE
SERVICE
TUNE.UP
PROCEDURE eE
4
gB
Y
@

Battery E Y
I
Inspection
1. Checkfor corrosionon the terminalsor loosecable
connections.
2. lf necessarycleanthe clampsandtightenfirmly.
3. Checkthal the electrolyte levelis betweenthe
UPPERand LOWERmarks.
Adddistilledwaterit necessary
Checkthe specificgravityby usinga hydrometer.
6 . lf the specificgravityreadingis 1.200or less,
rechargethe battery

UpperLine
Air CleanerElement
Removal
1. Disconnect the negativebatterycable.
2. Disconnect the wirehamessfromthe massair flow
(MAF)sensorby pushingon the wireclip.
3. Slidethe data linkconnector(DLC)ofi the holderon
the air intakehousing.
4. Removethe six upperair intakehousingbolts.
* Notice
Lift the upperair intakehousing carelullyso that the
air intake hose doesnot bend too much.
5. Removethe air cleanerelement.
Inspection
1. Msuallycheckthe air cleanerelementfor excessive
dirt,damageor oil.
* Notice
Do not usecompressedair to clean the air cleaner
element.
2. lf necessarycleanor replacethe air cleanerelement.
Installation
1. Installthe air cleanerelementintothe lowerair intake
housingwiththe rubberedgefacingupward.
2. Placethe upperair intakehousingon topof thelower
housing.
3. Installthe six upperair intakehousingboltsand
tightento specitication.
Tighleningtorque:
38 - 56 lbin (4 - 6 N.m)
4. Slidethe DLCbackontothe holderlocatedon the air
intakehousing-
5. Reconnectthe wirehamessto the MAFconnector.
6. Reconnectthe negativebatterycable.

SparkPlug
Removal
1. Disconnect
the negativebatterycable.
2. Removeair intakeassembly.Referto Englne
Removal,page10-33.
3. Removeacceleratorcablebracket.Referto Enolne
Removal,page10-33.
4. Removesix boltsandcoilcoverfromcvlinderhead
cover.
5. Removefourbottsandthe two coilsfromthecover.
 FE DOHCENGINE 1O-7
6 . Disconnect
the hightensionleadstromthe spark
plugsby twistingthe bootand removing. W€ar and Adhesion
7. Usecompressed ol Carbon
air to removeanydirtfromaround
the sparkplughole.

Installation
1. Applyanti-seize compound to the sparkplug
threads.
Makesurethe sparkplugsocketfits squarelyon the
sparkplug,thenremove. 2. Installthe sparkplugsintothe cylinderheadand
tightento specification.
Tighteningtorque:
11-17lb-ft(15- 23 N.m)
3. Reconnect hightensionleads.
hstallthe two coilsandsecurewithfourbolts.
E Installthe coilcoverandsecurewithsix bofts.
6 . fnstallthe acceleratorcablebracket.Referto Enoine
I nstallation,page 10-82.
7. lnstallair intakeassembly. Relerto Engine
lnstallation,page 10-82.
8. Reconnect the negativebatterycable.

lnspection
1. Checkfor thefollowing:
a. Damagedinsulation
b. Womelectrodes
c. Carlcondeposits
d. Damaged gaskets
e. Bumtsparkinsulator
f. Pluggap
Plug gap:
0.039- 0.043inch (1.G1.1mm)
2. Cleanor replaceif necessary
1O-8 FE DOHCENGINE

EngineOil
Inspection 1l: ..
1. Makesurethatthe vehicleis on levelground.
2. Startthe engineand let it warmup to normal
operating temperature.
3. Tumthe engineoff.Waitfor 5 minutes-
fi Notice
lf you do not wait, the engine oil dipstickmight not
show the actual level.

K59SOBt0

3. lf the coolantlevelis belowthe radiatorfillerneck,add

enoughcoolantto bringthe levelup to thefillerneck.
4. Installthe radiatorcap.Makesure it is seatedfirmly.
5. Verifythat the coolantlevelis nearlhe F lineon the
coolantfluid reservoir (engineat operating
temperature).
6. lf the coolantlevelis belowthe F line,thenremovethe
coolantfluid reservoir capand add enoughcoolantto
bringthe levelup to the F line.
7. Re-installthe coolantfluidreservoircao.
4 . Removethe engineoil dipstickandcleanil witha
snoprag. DriveBelts
Fullyinsertthe engineoil dipslickandremoveit again, Inspection
keepingthe tip pointeddown. 1. Checkthe drivebettsfor wear,cracksor fraying.
!F Notice 2. Replaceif necessary.
Do not add too much oil. lf the oil level is above the 3. Verifythat the drivebeltsare conectly mountedon the
"F line, the engine could be damaged.
pulleys.
lf the oil levelis at or belowthe L line,addenoughoil
V-Belt
to bringit up to the F line.
I I
EngineCoolant l'z____tt
FlI
Inspection Correct
1. Makesurethatthe engineis cold.
'f, Caution
V-RibbedBell
Never remove the radiator cap when the engine
is hot.
l l l r t l
2. Removethe radiatorcap andverifythatthe coolant
levelis nearthe radiatorfillerneck. ry! h444,r 7@
lncorect Correcl Inco.rect

(59SOAr1

4. Checkthe drivebeftdeflectionby applyingmoderate

pressure(22lb [98 N])midwaybetweenthepulleys.
a. Measurelhe beltdeflectionbetweenthesoecified
pulleys.
.new' if it hasbeenusedon a
b. A belt is considered
runningenginefor lessthanfive minutes.
 FE DOHCENGINE 10.9

c. Checkthe beltdeflectionwhentheengineis cold

or at least30 minutesafterthe enginehas
stopped.
NC
BELT NEW USED Compressor
inch (mm) inch (mm)
Generator 0.24- 0.31 0.27- 0.35
(6-8) (7-s)
P/S 0.31- 0.39 0.35- 0.43
(8-10) (s-11)
NC 0.27- O.35 0.31- 0.39
(7-s) (8-10)

22 rb(98N)

Generator

Generator
DriveBelt
1. To removethe generatordrivebeft,removethe air
conditioningdrivebelt first. Relerlo Air Conditioning
Crankshatt Dive Belt,page10-9.
Pulley
2. lf adjustment or removalis ne@ssaryloosenthe
mountingbolts(A and B) fromthe backsideof the
generatorand adiustthe deflection bytumingthe
adiustingbolt(C).
3. Aftermakingthe ad,ustment, tightenthemounting
bons(Aand B) to specification.
Crankshaft Tighteningtorque:
Pulley A: 16 lbft (22 N.m)
B: 32 lb-ft (45 N.m)

Crankshaft
Pulley

5. lf the deflection
is notconect,adjustthe belt.
PowerSteeringDriveBelt
Air Conditioning
DriveBelt
1. To removethe powersteeringdrivebelt,the air
1. lf adjustment or removalis necessaryloosenthe conditioningandgeneratordrivebeltsmustbe
locknut(A)andadiustthe deflection by tumingthe removedfirst. Refetlo Air Conditioning
Drive Belt,
adiustingbott(B). page10-10,andGeneratorDriveBelt,page 10-11.
2. Aftermakingthe adjustment, tightenthe locknut(A) 2. lf adjustmentor removalis necessaryloosenthe
to specification. lockbolt(A)and mountingbolt(B)andadiustthe
Tighteninglorque: defleclionby pryrngon the powersteeringpumpwith
23 - 25 rb-ft(31- 34 N.m) a suitablelever.
10-10 FE DOHCENGINE

3. Aftermakingthe adjustment, tightenthe lockbolt (A) :F Notice

and mountingbolt(B)to specification.
lgnition timing cannotbe adjusted.
Tighteningtorque:
lgnitiontiming:
27 - 34 ltsft (37- 46 N.m)
4 ! 6 degrees(at idle speed)

5 . Removethe timinglightfromthe engineandre-install

High-Tension
Lead accesscoveron coilcover.
Inspection Tumthe engineoff.
1. Checkforthefollowing:
a. Damagedlead ldle Speed
b. Carbondeposits lnspection
2. Cleanor replaceif necessary 1. Applythe parkingbrake.
2. Startthe engineandlet it warmup to normaloperating
Iemperalure.
q
Tumotf all electricalloads.
Openthe coverto thedatalinkconnector(DLC)
locatedon the air intakehousing.
5 . Connecta tachometer to the lc-terminalof the DLC.
* Notice
The idle speed is controlledautomaticallyby the
enginecontrol modulethroughthe idle air control
(IAC) valve, thereforethe idle speed cannotbe
adjusted.
6. Checkthatthe idlespeedis withinthe specifiedrange.
ldle speed(transmissionin neutral):
800 r 5{t RPM
.9, 7. Removethe tachomeler tromthe DLClc-terminal.
1 8. Closethe coverto the DLC.
:r. Tumoff the engine.
lgnitionTiming
Inspection
1. Startthe engineand let it warmup to normal
operatingtemperature.
2. Tumoff all electricalloads.
3. Removethe accesscoveron lhe coilcoverand
connectthe timinglightto No. t hightensionwire.
4. Verifythat the ignitiontimingis withinspecification.
 FE DOHCENGINE 1O-11

7. Startingwiththe compression gaugeat zero,fully

lG Terminal depressthe accelerator pedalandcrankthe engine
for aboutl0 seconds.
8. Recordthe maximumgaugereading.
9. Checkthe compression at eachcylinder.
tF Notice
? ????300 The maximumdifferencein compressionbetween
cylindersshouldbe 26 psi (196kPa).
Normalcompression:
164psi (1,128kPa)
Minimumcompression:
114psi (790kPa)
1 0 .lf the compression in one or morecylindersis low,
poura smallamount(aboutonetablespoon) of
engineoil intothe cylinderand recheckthe
comoression.
Compression a. lf thecompression increases,thepiston,the
pistonringsor the cylinderwallmaybe wom.
Inspection b. lf thecompression remainslow a valvemaybe
1. Checkrhatthe bafteryis fullycharged. stuckor seatedimproperly.
2. Rechargeif necessary c. lf the compression in adjacentcylinders
remains
3. Startthe engineand allowit to reachnormal low,the cylinderheadgasketmaybe defectiveor
operatingtemperature. the cylinderheaddistorted.
4. Tumthe engineoff and waitabout10 minutesto 1 1 .Re-install thesparkplugs,reletlo SparkPlug
allowihe exhaustmanifoldto cool. Installation, page 10-7.
5. Removethe sparkplugsand inspect.Referto Spark
Plug,page 10-6.
6. Connecta campression gaugeto the No. 1 spark
plughole.
10.12 FE DOHCENGINE

TIMINGBELT

'w
6P

R\ \Fr

a€ --'r'-.r
./

-r/

'I. CrankshaftPulley 6. TimingBeltTensioner Pulleyand

2. ThermostatAssemblv Spring
3. UpperTimingBeltCover 7. TimingBeltldlerPulley
4. LowerTimingB€ltCover 8. TimingBelt
5. TimingBeftGuidePlate 9. CamshaftPulleys
10. TlmingBeltPulley
 FE DOHCENGINE 10.13

TimingBelt
Removal
1. Disconnectthe negativebatterycable.
2. Removethe two treshair ductmountingboltson the
radiator.
3. Loosenthe treshair ductclampat the intakehousing.
4. Removethe hoseat the resonance chamber.
5. Removethe Jreshair duct.

T/M Fan
yI

*< 9. Loosenthetwo generatormountingbolts(A andB).

6. Removethe fivecoolingtan shroudbolts.

10. Loosenthe generatordrivebeltfromthegenerator

the adjustingbolt(C).
by loosening
11. Removethe generator drivebelt.
12. Removethe tan oullev

7. Removethe tourthermo-modulated
fan nuts.
8. Removethe thermo-modulated
fan and coolinofan
shroudat the sametime.
10-14 FE DOHCENGINE

13. Removethe foursplashguardmountingboltsand 17. Removethe powersteeringbelt.

splashguard. 18- Bemovefiveboltsand the uppertimingbeltcover.
Reierlo TimingBelt,page10-12. (
19. Removetwo boltsand the lowertimingcover.Refert
TimingBelt,page10-12.
20. Loosenthetensionerlockboltand oivotthetensioner
pulleyoutwardto removethe tensiontromthetiming
belt,thenre-tightenthe tensionerlockbolt.
TighteningTorque:
27-38lb.fi (37-s2N.m)

14. Loosenthe A,/Cidlerpulleynut (A).

Compressor

K59SOB135

21 Markthe timingbettrotationfor properreinstallation

it
it is reused.
22. Removelhe timingbelt.
2 Caution
Be careful not to allow oil or greaseon the belt.

15. Removethel./C drivebettby loosening

theadlusting
boh. Markthe
16. Loosenthe powersteeringpumplockboltandmountingbott. Directionot
Rotation
 FE DOHCENGINE 10.15

Installation 3. Installthe timingbeltso that thereis no looseness at

1. Alignthetimingbeltpulleyandthe pumpbody the tensionside,andat the two camshaftpulleys.
'/,
alignmentmarks. Caution
. lt the timing belt is being rcused,it must be
reinstalled to rotate in the original dircction.
. Check that there is no oil, greas, or dirt on
the timing belt.

[ \ \ \

[-j tl

x59SO8260

Alignthe matingmarkson the camshaftpulleyswith

the alignmentmarkson the sealplate.
fi Notice
For intakeside camshaftpulley,align I ma*.
4 . Loosenthe tensionerlockbolt.
For exhaustside camshaftpulley,align E mark.
Tum the crankshaft twocomDleterevolutions in the
of rotation.
direc'tion
6 . Checkthatthe matingmarksare correctly aligned.lf
not alignedconectly,removethe timingbeltand
tensione(and retumto step 1.

StogA?94
o o \lcl
r_,tt r.:/\-/
7 . Turnthe crankshaft to alignthe S ma* of the
exhaustcamshaftpulleywiththe s€alplatemating
mark.

K595O8259

w rc Lq
@(
t)z

K59SOB263
10-16 FE DOHCENGINE

Tightenthe timingbelttensionerlockbolt. 14. Installthe fan pulley.

Tighteningtorque: 15. lnstallthe generatordrivebeltand adjustbelt
27 - 38 lb-ft (37- 52 N.m,3.8 - 5.3 kg-m) deflec'tionby tightening
adjustingbolt(C).
9. Checkthe timingbeltdeflection.It the deflectionis Generator Belt deflection:
notcorrect,loosenthe tensionerlockboltand repeat New:0.24- 0.31in. (6 - I mm)
sleps5-7 above.Feplacethe tensionerspringif Used:0.27- 0.35in. (7 - 9 mm)
necessary.
16. Tghtengenerator mountingbolts(A andB).
Belt deflection
0.30- 03il in. f.5 - 8.5mmy22lb (98N,10kg) Tighteningtorque:
A: 16 lb.ft (22N.m)
B: 32 lb-ft (45N.m)

5?@%
R'% o-o
10. Installthe lowertimingbeltcoverandtwo bolts.Refer
lo TimingBelt,page10-12.
Tighteningtorque: 1 7 .lnstallA,/Cdrivebeltand set bett deftectionbv
61 - 87 lFin (7 - 10 N.m) tighteningadjustingbolt(B).
11. Installthe uppertimingbeltcoverandfivebolts. A,/CBelt deflection:
Retetto nming Belt,page10-12. New:0.27- 0.35in. (7 - 9 mm)
Used:0.31- 0.39in. (8 - 10 mm)
Tighteningtorque:
61 - 87 lb-in (7 - 10 N.m) 1 8 . Tightenthe adjusting boh(B) and idlerpulleybott(A).
12. Installthe powersteeringdrivebeltand set belt Tighteningtorque:
deflection. 23 - 25 lb-ft (31- 34 N.m)
PowerSteeringBelt deflection:
New: 0.31- 0.39in. (8 - 10 mm)
Used 0.35- 0.43in. (9 - 11 mm)
13. Tightenthe lockbolt(A) and mountingbott(B). A/C
Compressor
l'ightening torque:
27 - 34 lb-ft (37- 46 N.m)
 FE DOHCENGINE 10-17

1 9 .Installthesplashguardandtightenthe four mounting z,t,lnstallthe freshair duct.

bolts. 24. Installthe hoseat the resonance chamber.
n. lnstallthefan andfan shroud. 25. lnstalland tightenthe clampat the ak intake
2 1 .lnstallthefourlan boltsandtighten. housing.
TighteningTorque: 26. lnstallthe twolreshair ductmountingboltsand
24 lbft (32.6N.m) tighten.
Tighteningtorque:
69 - 95 lb.in (7.8-11N.m)

I
l'
I
T,'M FAN
uil |<59SOB'i

22. Inslallthefivefan shroudmountinobolts.

Tighteningtorque:
69 - 95 lb.in (7.8 -11N.m)
27. Reconnect
the negativebatterycable.

K59SOB3o
10-18 FE DOHCENGINE

TIMING
BELTPULLEY CAMSHAFTPULLEYS
Removal Removal
1. Referto TimingBelt Removalpage10-13. 1. Referto TimingBeftHemoyal,page 10-13.
2. Removethe timingbeltpulleylockbolt. 2. Removethe camshattpulleylockbolts.
3. Removethe timingbeltpulley. 3. Bemovethe camshaftpulleys.
Installation
1. Installthe timingbeltpulleywiththe matingmarks
aligned.

lh
l',rating '.'

-.Mm
Marks

6r \),
do

Installation
1. Installthe camshaftpulleysas shownin the
illustration,
makingsurethatthe dowelpinsand I
(intake)and E (exhaust) marksare pointingup.
2. Installthe camshaftpulleylockboltsandtighten.
2. Positionthe guideplaleas shown.
Tighteningtorque:
35 - 48 lb-ft (47- 65 N.m)

(59SO438

3. Installthe lockboltandtighten. Retetto TimingBeltlnstallation,

page10-15.
Tighteningtorque:
120lb-ft (162N.m)
Installtimingbeltas describedin thissection.
 FE DOHCENGINE 10-19

CYLINDERHEAD

ry,
\x

& -\o
. K59SO840

1. lgnitionCoilsand HighTension 7. HydraulicLashAdiuster i3. OuterValveSpring

Leads 8. CylinderHeadBolt 14. InnerValveSpring
2. CylinderHeadCover g. CylinderHead 15. LowerSpringSeat
3. CamshaftPositionSensor 10. CylinderHeadGasket 16. Valve
4. SealPlate ll. ValveLocks 17. ValveStemSeal
5. CamshaftCaps 12. UpperSpringSeat 18. VatveGuide
6. Camshafts
 10-20 FE DO}ICENGINE

CYLINDERHEADCOVER 10. Removethe fourbolts(twoeach)fromth€ignition

coilsto the cylinderheadcover.
Removal
11. Removethesparkplugwirestromthesparkplugs. {,'.,
1. Disconnect the negativebatteryterminal.proceedto
removethe hoseat the resonance chamber. 12. Removethe 15 cylinderheadcoverbolts.
2. Removeone boltand the resonance chamber,then
removelhe two acceleratorcablebracketboltsfrom
the cylinderheadcover.

o8o b

Bolts

K59SO895

13. Removethe cylinderheadcover.

lnstallation
1. Placea smallamountof sealerat the comersof the
8N7At(pol floatcamshaftcapsandthe distributormounting
caD.
Removethe two air intaketubes-to-cvlinder head
coverbolts.
Disconnect the acceleratorcableby pullingbackon
the throttleshaftand rotatingthe acceleratorcable
untilit linesup withthe slotin the pu ey.
5. Loosenthe air hoseclampfromthe air intakehose
to the MAFsensor
Removethe IACand breatherhoses,andthe
vacuumlinefromthe air intaketube.
7. Removethe threeboltsfromthe air intaketubeto
the throttlebodyand removethe air intaketube and
air intakehoseas an assembly.
8. Removethe six coilcoverboltsfromthetop ot the
cylinderheadcover.
Disconnec,t fie electri(El
connectors
fromtheignitioncoils.

Placecylinderheadcoveron top of cylinderhead.

Securecoverwith15 boltsandtightento
specification.
Tighteningtorque;
35 - 52 ltsin (4- ON.m)
4. lnstallthe ignitioncoilsandconnectthe sparkplug
wiresto the sparkplugs.
Fastenthe two coilsto thecylinderheadcoverwith
the four mountingboltsandtightento specification.
Tighteningtorque:
60 lb-in (6.8 N.m)
Connectthe two ignitioncoilconnectors.