Distributor: Service and Repair

REMOVAL:

1. Disconnect negative battery terminal.

Draining Intercooler:

2. Remove intercooler filler cap. Drain coolant from engine and intercooler.

3. Disconnect two intercooler radiator hoses and the reservoir tank water hose.

4. Disconnect the intercooler coolant level warning sensor connector.

Intercooler Removal:

5. Loosen the two hose clamps, and remove the three intercooler retaining bolts.

6. Disconnect the air hoses, and remove the intercooler with the air hose connected.

7. Disconnect distributor connector.

Ignition Wire Removal And Installation:

8. Remove secondary ignition wires from spark plugs and ignition coil.

Ignition Wire Clamp:

9. Remove the bolt retaining secondary ignition wire clamp.

Distributor Hold Down Bolt Removal And Installation:

10. Remove the two distributor hold down bolts. Remove distributor from cylinder head.

Distributor O-ring:

11. Remove and discard distributor O-ring.

INSTALLATION:

TDC Timing Marks:

1. Rotate crankshaft to align timing mark on crank pulley with the TDC mark on the timing belt cover. Ensure position of the slit in the intake camshaft.

Distributor O-ring:

2. Lightly coat a new distributor O-ring with engine oil prior to installation.

Distributor Mating Marks:

3. Align the cutout on the distributor shaft with the groove on the distributor housing. Install the distributor in the cylinder head.

4. Install and lightly tighten the two distributor hold down bolts.

Ignition Wire Clamp:

5. Install and tighten the secondary ignition wire clamp.

6. Connect the secondary ignition wires to the spark plugs and ignition coil. Ensure proper firing order.

Firing Order: 1 - 3 - 4 - 2

7. Reconnect the distributor connector.

8. Install the intercooler, three water hoses, two air hoses, and the coolant level sensor connector.

CAUTION: Do not reuse coolant. Reduction in coolant strength may result in rust occuring. Use a good brand of ethylene-glycol base coolant. Mix coolant according to manufacturer's directions.

9. Reconnect the negative battery terminal.

10. Fill intercooler reservoir tank. Turn ignition switch to the on position and open throttle valve.

Intercooler Capacity: 1.7 quarts (1.6 liters)

NOTE: As the throttle valve opens it operates the intercooler water pump. Fill intercooler reservoir till the coolant level remains the same when the water pump is switched from off to on.

11. Install the intercooler filler cap.

12. Adjust ignition timing. Refer to ADJUSTMENT PROCEDURES.

13. Start and race engine to approximately 3,000 RPM a few times. Stop engine. Recheck and refill intercooler.

14. Leave the engine and intercooler water pump stopped for approximately 20 minutes. Recheck intercooler coolant level and refill if necessary.