
Contents
Reference...................................................135
DescriptionandOperation.............................136
ComponentLayout.....................................136
Description................................................147
Operation..................................................149
ServiceProcedures.........................................152
CylinderHeadOverhaul-withCylinder
HeadRemoved...........................................152
CrankshaftOverhaul-withEngine
Removed....................................................157
ConnectingRodBearingsOverhaul.............161
Pistons&Liners..........................................163
CrankshaftRearOilSeal.............................166
CrankshaftFrontOilSeal............................167
Flywheel-ManualT ransmission...................168
T orqueConverterDrivePlate-Automatic
T ransmission..............................................168
CylinderHeadGasketOverhaul-with
EngineRemoved.........................................169
CamshaftCoverGasket..............................173
Valves........................................................174
HydraulicT appets.......................................178
Camshafts-InletorExhaust.......................178
IntakeManifoldGasket................................180
1.8VCTExhaustManifoldGasket................182
OilPump...................................................184
EngineOilandOilFilter..............................185
EngineOilPressureCheck..........................186
OilPick-UpStrainer.................................186
EngineSump...............................................187
CamshaftDriveBeltCover-Front
Upper........................................................188
CamshaftDriveBeltCover-Rear
Upper........................................................188
CrankshaftPulley........................................189
EngineMounting-RH.................................190
EngineMountingLowerTieRod.................191
1.8VCTCamshaftFrontOilSeal-
Exhaust......................................................191
1.8VCTCamshaftFrontOilSeal-
Inlet...........................................................192
1.8VCTCamshaftDriveBelt(New)............192
1.8VCTCamshaftPhaserUnit.....................195
1.8VCTEngineandManual
T ransmission..............................................196
1.8VCTEngineandAutomatic
T ransmission..............................................200
1.8VCTSolenoid-ExhaustCamshaft...........205
1.8VCTSolenoid-InletCamshaft...............205
1.8VCTSolenoidHousing-Exhaust
Camshaft....................................................206
1.8VCTSolenoidHousing-Inlet
Camshaft....................................................206
1.8VCTCylinderHeadGasketNew............207
SpecialT ools..................................................210
EngineCoolingSystem.....................................213
Specications.................................................213
T orque.......................................................213
Reference...................................................214
DescriptionandOperation.............................215
SystemComponentLayout.........................215
Description................................................218
Operation..................................................220
ServiceProcedures.........................................223
Coolant-DrainandRell...........................223
ExpansionT ankCap-PressureT est..............224
System-PressureT est................................225
CoolantExpansionT ank..............................226
FanAssembly.............................................227
CoolingFanResistor..................................229
RadiatorAssembly......................................229
SupplyFluidCoolerHose-Automatic
T ransmission..............................................231
ReturnFluidCoolerHose-Automatic
T ransmission..............................................232
Thermostat................................................233
Pump-Coolant............................................233
SpecialT ools..................................................234
EngineManifold&ExhaustSystem.................235
Specications.................................................235
T orque.......................................................235
DescriptionandOperation.............................236
SystemComponentLayout-1.8TInletand
ExhaustSystem..........................................236
SystemComponentLayout-1.8VCTInlet
andExhaustSystem....................................242
Description-1.8TInletandExhuast
System.......................................................247
Description-1.8VCTInletandExhuast
System.......................................................248
Operation-1.8TInletandExhuast
System.......................................................249
Operation-1.8VCTInletandExhaust
System.......................................................250
ServiceProcedures.........................................251
AirCleaner................................................251
2Version2.0