Part 1
WARNING: Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work.
TIMING BELT
NOTE: The 1.5 Protege engine is a dual overhead cam engine despite it's outward appearance. Once the cam cover (valve cover) is removed both camshafts and their drive system can be observed.
The right camshaft is driven by the timing belt and a sprocket bolted to the shaft. The left camshaft is driven by a chain and sprockets connected to the right camshaft.
When making repairs to engine timing components or the cylinder head it is adviseable to inspect and adjust this drive chain or make any repairs needed.
Timing Components:
1. Disassemble in the order shown in the image.
2. Assemble in the reverse order of disassembly.
DISASSEMBLY NOTE
CRANKSHAFT PULLEY AND PLATE
1. Hold the flywheel (Manual Transaxle [MTX]) or drive plate (Automatic Transaxle [ATX]) by using the SST.
2. Remove the crankshaft pulley and plate.
PULLEY BOSS
1. Turn the crankshaft clockwise and align the timing marks of the pulleys.
NOTE:
- Face the locating pin on the pulley boss and "Z" mark on the camshaft pulley straight up, and align the timing marks with the cylinder head upper surface.
2. Hold the flywheel (MTX) or drive plate (ATX) by using the SST.
3. Remove the pulley boss.
TIMING BELT
CAUTION:
- The following will damage the belt and shorten its life; Forcefully twisting it, turning it inside out, or allowing oil or grease on it.
1. Mark the timing belt rotation on the belt for proper reinstallation.
2. Loosen the tensioner lock bolt.
3. Push the tensioner in the direction of the arrow and hand tighten the lock bolt.
4. Remove the timing belt.
ASSEMBLY NOTE
TIMING BELT PULLEY AND KEY
Insert the key into the timing belt pulley, facing the tapered side downward. Push the key until it stops.
TENSIONER AND TENSIONER SPRING
1. Install the tensioner spring as shown.
2. Push the tensioner in the direction of the arrow and hand tighten the lock bolt.
TIMING BELT
1. Verify that all timing marks are correctly aligned.
NOTE:
- Face "Z" mark on the camshaft pulley straight up and align the timing marks with the cylinder head upper surface.
2. Install the timing belt on the pulleys in the order shown below.
1) Timing belt pulley
2) No.2 idler pulley
3) No.1 idler pulley
4) Camshaft pulley
5) Tensioner
PULLEY BOSS
1. Install the pulley boss and pulley lock bolt. Turn the crankshaft clockwise 1 and 5/6 times, and verify that the timing mark and the tensioner set mark (A) are aligned.
2. Loosen the tensioner lock bolt to apply tension to the timing belt. Do not apply tension other than that of the tensioner spring.
3. Tighten the tensioner lock bolt.
Tightening torque:
38 - 51 Nm (28 - 38 ft. lbs.)
4. Turn the crankshaft clockwise 2 and 1/6 times, and verify that all timing marks are correctly aligned.
NOTE:
- Timing is correct when the locating pin on the pulley boss and "Z" mark on the camshaft pulley are facing straight up, and the timing marks are aligned with the cylinder head upper surface.
5. Check the belt deflection at the point indicated by applying moderate pressure 98 Nm (22 lbs.).
Deflection:
7 - 9 mm (0.28 - 0.35 inch)
6. If the timing belt deflection is not correct, remove the timing belt and repeat from timing belt assembly note step 1.
7. Hold the drive plate (ATX) or flywheel (MTX) by using the SST.
8. Tighten the pulley lock bolt.
Tightening torque:
157 - 166 Nm (116 - 122 ft. lbs.)
CRANKSHAFT PULLEY AND PLATE
1. Hold the drive plate (ATX) or flywheel (MTX) by using the SST.
2. Install the crankshaft pulley and plate.
Tightening torque: 12.3 - 17.1 Nm (9.05 - 12.6 ft. lbs.)
CYLINDER HEAD COVER
1. Before installing the cylinder head cover, measure the valve clearances.
CAUTION:
- Silicone sealant hardens and causes oil leakage when it is left for an extended period.
2. Verify that the grooves on the cylinder head cover are free of oil, water and other foreign material.
3. Install the new cylinder head cover gasket into the cylinder head cover.
4. Apply silicone sealant to the shaded areas shown.
Thickness:
3 - 4 mm (0.12 - 0.15 inch)
5. Install the cylinder head cover.
6. Tighten the cylinder head cover bolts in five or six steps in the order shown.
Tightening torque:
6.9 - 10.7 Nm (61 - 95.4 inch lbs.)
7. Retighten the bolts in the order shown.
Tightening torque:
6.9 - 10.7 Nm (61 - 95.4 inch lbs.)
CYLINDER HEAD (I)
Upper Engine:
1. Disassemble in the order shown in the image.
2. Assemble in the reverse order of disassembly.
DISASSEMBLY NOTE
CAMSHAFT PULLEY
1. Hold the camshaft by using a wrench on the cast hexagon as shown, and loosen the camshaft pulley lock bolt.
2. Remove the camshaft pulley.
CAMSHAFT CAP
1. Loosen the front camshaft cap bolts in five or six steps in the order shown.
2. Remove the front camshaft cap bolts and the front camshaft cap.
3. Loosen the camshaft cap bolts in five or six steps in the order shown.
4. Remove the camshaft cap bolts and camshaft caps.
CAMSHAFT, TIMING CHAIN, AND CHAIN ADJUSTER
Before removing the camshaft, timing chain, and chain adjuster, inspect the following.
1) Camshaft end play
2) Camshaft journal oil clearance
CYLINDER HEAD
1. Loosen the cylinder head bolts in two or three steps in the order shown.
2. Remove the cylinder head.
ASSEMBLY NOTE
CYLINDER HEAD
1. Before installation, measure the length of each bolt. Replace any that exceed the maximum length.
2. Install the bolts and tighten them in two or three steps in the order shown.
Tightening torque:
17.2 - 22.0 Nm (12.7 - 16.2 ft. lbs.)
3. Put a paint mark on each bolt head.
4. Using the marks as a reference, tighten the bolts by turning each 85° - 95° in the sequence shown.
5. Further tighten each bolt by turning another 85° - 95°.
CAMSHAFT, TIMING CHAIN, AND CHAIN ADJUSTER
1. Apply clean engine oil to the camshaft journals, camshaft lobes, and camshaft gears.
2. Install the camshafts onto the cylinder head, aligning marks on the camshaft gear and the timing chain.
CAMSHAFT CAP
1. Apply silicone sealant to the shaded areas shown in the image.
Thickness:
1 mm (0.04 inch)
2. Install the camshaft caps to the positions from which they were removed.
3. Hand tighten the camshaft cap bolts marked (5), (7), (2), and (4).
4. Tighten the camshaft cap bolts in five or six steps in the order shown.
Tightening torque:
11.3 - 14.2 Nm (99.9 - 125 inch lbs.)
5. Apply clean engine oil to the lip of the new camshaft oil seal.
6. Push the oil seal slightly in by hand.
7. Tap the camshaft oil seal in evenly by using a pipe.
Protrusion:
IN: 0 - 0.4 mm (0 - 0.01 inch)
EX: 1.0 - 1.4 mm (0.04 - 0.05 inch)
NOTE:
- Oil seal outer diameter: 48.0 mm (1.89 inch)
- Oil seal inner diameter: 34.2 mm (1.35 inch)
SEAL CAP
1. Apply silicone sealant to the seal cap as shown.
Thickness: 3 - 4 mm (0.12 - 0.15 inch)
2. Install the seal cap.
CAMSHAFT PULLEY
1. Install the camshaft pulley so that the "Z" mark aligns with the knock pin.
2. Hold the camshaft by using a wrench on the cast hexagon, and tighten the lock bolt.
Tightening torque:
50 - 60 Nm (37 - 44 ft. lbs.)
CYLINDER HEAD (II)
1. Disassemble in the order shown in the image.
2. Assemble in the reverse order of disassembly.
DISASSEMBLY NOTE
VALVE KEEPER
1. Set the SST against the upper valve spring seat as shown.
2. Remove the valve keepers.
VALVE SEAL
Remove the valve seal by using the SST.
ASSEMBLY NOTE
WATER TEMPERATURE SENDER UNIT
1. Apply silicone sealant to the thread of the water temperature sender unit as shown.
2. Install the water temperature sender unit.
Tightening torque:
6.4 - 9.3 Nm (57 - 82 inch lbs.)