Distributor: Service and Repair

REMOVAL:

1. Disconnect negative battery terminal.

Intercooler Location:

2. Drain engine cooling system.

Intercooler Air Inlet:

3. Using a clip remover, remove the seven clips and air inlet.

Intercooler Protector:

4. Remove the three bolts and the intercooler protector.

Intercooler Removal:

5. Remove the two intercooler retaining bolts.

6. Disconnect the intercooler from the turbocharger and intake air connector. Remove the intercooler and air connector.

7. Disconnect distributor connector.

8. Disconnect the four secondary ignition wires from the clamps.

Ignition Wire Removal And Installation:

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

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 the secondary ignition wires in the clamps.

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, intercooler protector, and intercooler air inlet.

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. Fill engine cooling system.

10. Reconnect the negative battery terminal.

Coolant Capacity: 6.8 Quarts (6.4 Liters)

11. Adjust ignition timing. Refer to ADJUSTMENT PROCEDURES.