Engine Mechanical (H4DOTC): Diagnosis Subaru Baja I

INSPECTION

Scheme 386

1. After warming-up the engine, turn the ignition switch to OFF.
2. Make sure that the battery is fully charged.
3. Release the fuel pressure. Refer to «RELEASING OF FUEL PRESSURE»(ref-208372-S33426670002005120700000) , OPERATION, Fuel.
4. Remove all the spark plugs. Refer to «REMOVAL»(ref-208379-S08747413442005120700000) , Spark Plug.
5. Fully open the throttle valve.
6. Check the starter motor for satisfactory performance and operation.
7. Hold the compression gauge tight against spark plug hole. NOTE: When using a screw-in type compression gauge, the screw (put into cylinder head spark plug hole) should be less than 18 mm (0.71 in) long.
8. Crank the engine by means of starter motor, and then read the maximum value on the gauge when the pointer is steady.
9. Perform at least two measurements per cylinder, and make sure that the values are correct. Compression (350 RPM and fully open throttle): Standard 981 - 1,177 kPa (10 - 12 kgf/cm 2 , 142 - 171 psi) Limit 882 kPa (9.0 kgf/cm 2 , 128 psi) Difference between cylinders Less than 49 kPa (0.5 kgf/cm 2 , 7 psi)

1. Warm-up the engine.
2. Disconnect the brake vacuum hose, and then install the vacuum gauge to hose fitting on manifold.
3. Keep the engine at the idle speed, and then read the vacuum gauge indication.

By observing the gauge needle movement, the internal condition of engine can be diagnosed as described below.

Scheme 387

Vacuum pressure (at idling, A/C "OFF"): Less than -60.0 kPa (-450 mmHg, -17.72 inHg)

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1. Remove the oil pressure switch from engine cylinder block. Refer to «OIL PRESSURE SWITCH»(ref-208378-S06407647642005120700000) .
2. Connect the oil pressure gauge hose to cylinder block.
3. Connect the battery ground cable to battery.
4. Start the engine, and then measure the oil pressure. Oil pressure: 98 kPa (1.0 kgf/cm 2 , 14 psi) or more at 800 RPM 294 kPa (3.0 kgf/cm 2 , 43 psi) or more at 5,000 RPM If the oil pressure is out of specification, check oil pump, oil filter and lubrication line. Refer to «INSPECTION»(ref-208378-S06588518972005120700000) , Engine Lubrication System Trouble in General. If the oil pressure warning light is turned ON and oil pressure is in specification, replace the oil pressure switch. Refer to «OIL PRESSURE SWITCH»(ref-208378-S06407647642005120700000) . NOTE: The specified data is based on an engine oil temperature of 80°C (176°F).
5. After measuring the oil pressure, install the oil pressure switch. Refer to «INSTALLATION»(ref-208378-S25328462942005120700000) , Oil Pressure Switch.

Tightening torque

25 N.m (2.5 kgf-m, 18.1 ft-lb)

Note. If out of specification, check or replace the pressure regulator and pressure regulator vacuum hose.

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1. Release the fuel pressure. Refer to «RELEASING OF FUEL PRESSURE»(ref-208372-S33426670002005120700000) , OPERATION, Fuel.
2. Open the fuel flap lid, and then remove the fuel filler cap.
3. Disconnect the fuel delivery hoses, and then connect the fuel pressure gauge.
4. Connect the connector of fuel pump relay.
5. Start the engine.
6. Measure the fuel pressure while disconnecting the pressure regulator vacuum hose from intake manifold. Fuel pressure: Standard; 284 - 314 kPa (2.9 - 3.2 kgf/cm 2 , 41 - 46 psi)
7. After connecting the pressure regulator vacuum hose, measure the fuel pressure. Fuel pressure: Standard; 230 - 260 kPa (2.35 - 2.65 kgf/cm 2 , 33 - 38 psi) NOTE: The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kgf/cm 2 , 1 to 3 psi) higher than standard values during high-altitude operations.

Inspection and adjustment of the valve clearance should be performed while engine is cold.

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1. Set the vehicle on a lift.
2. Disconnect the ground cable from battery.
3. Remove the air intake duct. Refer to «REMOVAL»(ref-208374-S40795323462005120700000) , Air Intake Duct.
4. Remove the bolts which secure the timing belt cover (RH).
5. Lift-up the vehicle.
6. Remove the under cover.
7. Loosen the remaining bolts which secure the timing belt cover (RH), and then remove the timing belt cover.
8. Lower the vehicle.
9. When inspecting the #1 and #3 cylinders: Pull out the engine harness connector with bracket from air cleaner upper cover. Remove the air cleaner case. Refer to «REMOVAL»(ref-208374-S06540615662005120700000) , Air Cleaner. Disconnect the ignition coil connector. Remove the ignition coil. Place a suitable container under the vehicle. Disconnect the PCV hose from rocker cover (RH). Remove the bolts, and then remove the rocker cover (RH).
10. When inspecting the #2 and #4 cylinders: Disconnect the battery cable, and then remove the battery and battery carrier. Remove the bolt which secures the engine harness bracket onto body. Disconnect the washer motor connectors. Remove the washer tank mounting bolts. Move the washer tank upward. Disconnect the ignition coil connector. Remove the ignition coil. Place a suitable container under the vehicle. Disconnect the PCV hose from rocker cover (LH). Remove the bolts, and then remove the rocker cover (LH).
11. Turn the crankshaft pulley clockwise until arrow mark on the camshaft sprocket is set to position shown in the figure. NOTE: Turn the crankshaft using socket wrench.
12. Measure the #1 cylinder intake valve and #3 cylinder exhaust valve clearance by using thickness gauge (A). NOTE: Insert the thickness gauge in as horizontal a direction as possible with respect to the shim. Measure the exhaust valve clearances while lifting-up the vehicle. Valve clearance: Intake: 0.20 +0.04 -0.06 mm (0.0079 +0.0016 -0.024 in) Exhaust: 0.35+/-0.05 mm (0.0138+/-0.0020 in) NOTE: If the measured value is not within specification, take notes of the value in order to adjust the valve clearance later on.
13. If necessary, adjust the valve clearance. Refer to «ADJUSTMENT»(ref-208375-S08584625972005120700000) .
14. Further turn the crankshaft pulley clockwise. Using the same procedures described previously, and then measure the valve clearances again. Set the arrow mark on camshaft sprocket to position shown in the figure, and then measure the #2 cylinder exhaust valve and #3 cylinder intake valve clearances. Set the arrow mark on camshaft sprocket to position shown in the figure, and then measure the #2 cylinder intake valve and #4 cylinder exhaust valve clearances. Set the arrow mark on camshaft sprocket to position shown in the figure, and then measure the #1 cylinder exhaust valve and #4 cylinder intake valve clearances.
15. After inspection, install the related parts in the reverse order of removal.

Tightening torque

33 N.m (3.4 kgf-m, 25 ft-lb)

Scheme 406

Make sure there are no cracks or other damage.

Scheme 407

1. After removing the engine from body, secure it in the ST shown below. ST1 498457000 ENGINE STAND ADAPTER RH ST2 498457100 ENGINE STAND ADAPTER LH ST3 4998170 00 ENGINE STAND
2. In this section the procedures described under each index are all connected and stated in order. It will be the complete procedure for overhauling of the engine itself when you go through all steps in the process. Therefore, in this section, to conduct the particular procedure within the flow of a section, you need to go back and conduct the procedure described previously in order to do that particular procedure.

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1. Remove the V-belt cover.
2. Loosen the lock bolt (A).
3. Loosen the slider bolt (B).
4. Remove the front side belt (C).

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1. Loosen the lock nut (A).
2. Loosen the slider bolt (B).
3. Remove the A/C belt.
4. Remove the A/C belt tensioner.

1. Replace the belts, if cracks, fraying or wear is found.
2. Check the drive belt tension and adjust it if necessary by changing generator installing position and/or idler pulley installing position.

Belt tension (With using belt tension gauge)

(A)

replaced: 618 - 755 N (63 - 77 kgf, 139 - 170 lb)

reused: 490 - 640 N (50 - 65 kgf, 110 - 144 lb)

(B) : with air conditioner

replaced: 740 - 880 N (75 - 90 kgf, 166 - 198 lb)

reused: 350 - 450 N (36 - 46 kgf, 78 - 101 lb)

Scheme 412

Belt tension

(A)

replaced: 7 - 9 mm (0.276 - 0.354 in)

reused: 9 - 11 mm (0.354 - 0.433 in)

(B) : with air conditioner

replaced: 7.5 - 8.5 mm (0.295 - 0.335 in)

reused: 9.0 - 10.0 mm (0.354 - 0.394 in)

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1. Remove the V-belt. Refer to «V-BELT»(ref-208375-S02582614092005120700000) .
2. Remove the crankshaft pulley bolt. To lock the crankshaft, use ST. ST 499977100 CRANKSHAFT PULLEY WRENCH
3. Remove the crankshaft pulley.

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1. Install the crankshaft pulley.
2. Install the pulley bolt. To lock the crankshaft, use ST. ST 499977100 CRANKSHAFT PULLEY WRENCH Clean the crankshaft pulley thread using an air gun. Apply engine oil to the crankshaft pulley bolt seat and thread. Tighten the bolts temporarily with tightening torque of 44 N.m (4.5 kgf-m, 33 ft-lb). Tighten the crankshaft pulley bolts. Tightening torque: 180 N.m (18.3 kgf-m, 132.7 ft-lb)
3. Confirm that the tightening angle of crankshaft pulley bolt is 65 degrees or more. If the tightening angle of crankshaft pulley bolt is less than 65 degrees, conduct the following procedures. CAUTION: If the tightening angle of crankshaft pulley bolt is less than 65 degrees, the bolt should be damaged. In this case, the bolt must be replaced. Replace the crankshaft pulley bolts and clean them. Crankshaft pulley bolt: 12369AA011 Clean the crankshaft thread using an air gun. Apply engine oil to the crankshaft pulley bolt seat and thread. Tighten the bolts temporarily with tightening torque of 44 N.m (4.5 kgf-m, 33 ft-lb). Tighten the crankshaft pulley bolts keeping them in an angle between 65 degrees and 75 degrees. NOTE: Conduct the tightening procedures by confirming the turning angle of crankshaft pulley bolt referring to the gauge indicated on timing belt cover.
4. Install the A/C belt tensioner.
5. Install the V-belt. Refer to «V-BELT»(ref-208375-S02582614092005120700000) .

1. Make sure the V-belt is not worn or otherwise damaged.
2. Check the tension of the belt. Refer to «INSPECTION»(ref-208375-S35298240502005120700000) , V-belt.

Scheme 417

1. Remove the V-belt. Refer to «V-BELT»(ref-208375-S02582614092005120700000) .
2. Remove the crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208375-S06250155732005120700000) .
3. Remove the timing belt cover (LH) (A).
4. Remove the timing belt cover (RH) (B).
5. Remove the front timing belt cover (C).

Scheme 418

1. Install the front timing belt cover (C). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
2. Install the timing belt cover (RH) (B). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
3. Install the timing belt cover (LH) (A). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
4. Install the crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208375-S06250155732005120700000) .
5. Install the V-belt. Refer to «V-BELT»(ref-208375-S02582614092005120700000) .

Make sure the cover is not damaged.

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1. Remove the V-belt. Refer to «V-BELT»(ref-208375-S02582614092005120700000) .
2. Remove the crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208375-S06250155732005120700000) .
3. Remove the timing belt cover. Refer to «TIMING BELT COVER»(ref-208375-S14270702252005120700000) .
4. Remove the timing belt guides. (MT model)
5. If the alignment mark and/or arrow mark (which indicates rotation direction) on timing belt fade away, put new marks before removing the timing belt as follows: Turn the crankshaft using ST, and align the alignment marks on crankshaft sprocket, intake camshaft sprocket (LH), exhaust camshaft sprocket (LH), intake camshaft sprocket (RH) and exhaust camshaft sprocket (RH) with notches of timing belt cover and cylinder block. ST 499987500 CRANKSHAFT SOCKET Using white paint, put alignment and/or arrow marks on the timing belts in relation to the sprockets. Z 1 : 54.5 tooth length Z 2 : 51 tooth length Z 3 : 28 tooth length
6. Remove the belt idler (A).
7. Remove the timing belt.

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1. Remove the belt idler (B) and (C).
2. Remove the belt idler No. 2.
3. Remove the automatic belt tension adjuster assembly.

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1. Preparation for installation of automatic belt tension adjuster assembly: NOTE: Always use a vertical type pressing tool to move the adjuster rod down. Do not use a lateral type vise. Push the adjuster rod vertically. Be sure to slowly move the adjuster rod down applying a pressure of 294 N (30 kgf, 66 lb). Press-in the push adjuster rod gradually taking more than 3 minutes. Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lb). Press the adjuster rod as far as the end surface of cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder. Do not release the press pressure until stopper pin is completely inserted. Attach the automatic belt tension adjuster assembly to the vertical pressing tool. Slowly move the adjuster rod down with a pressure of 294 N (30 kgf, 66 lb) until the adjuster rod is aligned with the stopper pin hole in the cylinder. With a 2 mm (0.08 in) dia. stopper pin or a 2 mm (0.08 in) (nominal) dia. hex bar wrench inserted into the stopper pin hole in the cylinder, secure the adjuster rod.
2. Install the automatic belt tension adjuster assembly. Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb)
3. Install the belt idler No. 2. Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb)
4. Install the belt idler. Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb)

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1. Preparation for installation of automatic belt tension adjuster assembly. Refer to «INSPECTION»(ref-208375-S24992187932005120700000) , Timing Belt Assembly.
2. Crankshaft and camshaft sprocket alignment. Align mark (A) on the crankshaft sprocket with mark on the oil pump cover at cylinder block. Align single line mark (A) on the exhaust camshaft sprocket (RH) with notch (B) on timing belt cover. Align single line mark (A) on the intake camshaft sprocket (RH) with notch (B) on timing belt cover. (Make sure double lines (C) on intake camshaft and exhaust camshaft sprockets are aligned.) Align single line mark (A) on exhaust camshaft sprocket (LH) with notch (B) on timing belt cover by turning the sprocket counterclockwise (as viewed from front of engine). Align the single line mark (A) on intake camshaft sprocket (LH) with notch (B) on timing belt cover by turning the sprocket clockwise (as viewed from front of engine). Ensure the double lines (C) on intake and exhaust camshaft sprockets are aligned. Ensure the camshaft and crankshaft sprockets are positioned properly. CAUTION: Intake and exhaust camshafts for this DOHC Engine can be independently rotated with the timing belts removed. As can be seen from the figure, if the intake and exhaust valves are lifted simultaneously, their heads will interfere with each other, resulting in bent valves. When the timing belts are not installed, four camshafts are held at the "zero-lift" position, where all cams on camshafts do not push the intake and exhaust valves down. (Under this condition, all valves remain unlifted.) When the camshafts are rotated to install the timing belts, #2 intake and #4 exhaust cam of camshafts (LH) are held to push their corresponding valves down. (Under this condition, these valves are held lifted.) Camshafts (RH) are held so that their cams do not push valves down. Camshafts (LH) must be rotated from the "zero-lift" position to the position where the timing belt is to be installed at as small an angle as possible, in order to prevent mutual interference of intake and exhaust valve heads. Do not allow the camshafts to rotate in the direction shown in the figure as this causes both intake and exhaust valves to lift simultaneously, resulting in interference with their heads.
3. Installation of timing belt: Align the alignment mark on timing belt with marks on sprockets in alphabetical order shown in the figure. While aligning marks, position the timing belt properly. CAUTION: Disengagement of more than three timing belt teeth may result in interference between the valve and piston. Ensure the belt's rotating direction is correct.
4. Install the belt idlers. Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb) NOTE: Make sure that the marks on the timing belt and sprockets are aligned.
5. After ensuring that the marks on the timing belt and sprockets are aligned, remove the stopper pin from tensioner adjuster.
6. Install the timing belt guide. (MT model) Temporarily tighten the bolts. Check and adjust the clearance between timing belt and timing belt guide. Clearance: 1.0+/-0.5 mm (0.039+/-0.020 in) Tighten the bolts. Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb) Tightening torque: 6.4 N.m (0.7 kgf-m, 5.1 ft-lb) Tightening torque: 6.4 N.m (0.7 kgf-m, 5.1 ft-lb) Tightening torque: 6.4 N.m (0.7 kgf-m, 5.1 ft-lb)
7. Install the timing belt cover. Refer to «TIMING BELT COVER»(ref-208375-S14270702252005120700000) .
8. Install the crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208375-S06250155732005120700000) .
9. Install the V-belt. Refer to «V-BELT»(ref-208375-S02582614092005120700000) .

1. Check the sprocket teeth for abnormal wear and scratches.
2. Make sure there is no free play between sprocket and key.
3. Check the crankshaft sprocket notch used for sensor for damage and contamination of foreign matter.

Scheme 453

1. Remove the V-belt. Refer to «V-BELT»(ref-208375-S02582614092005120700000) .
2. Remove the crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208375-S06250155732005120700000) .
3. Remove the timing belt cover. Refer to «TIMING BELT COVER»(ref-208375-S14270702252005120700000) .
4. Remove the timing belt assembly. Refer to «CRANKSHAFT SPROCKET»(ref-208375-S38349563822005120700000) .
5. Remove the camshaft sprocket. Refer to «CAMSHAFT SPROCKET»(ref-208375-S14426545902005120700000) .
6. Remove the crankshaft sprocket.

Scheme 454

1. Install the crankshaft sprocket.
2. Install the camshaft sprocket. Refer to «CAMSHAFT SPROCKET»(ref-208375-S14426545902005120700000) .
3. Install the timing belt assembly. Refer to «INSTALLATION»(ref-208375-S23626259932005120700000) , Timing Belt Assembly.
4. Install the timing belt cover. Refer to «TIMING BELT COVER»(ref-208375-S14270702252005120700000) .
5. Install the crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208375-S06250155732005120700000) .
6. Install the V-belt. Refer to «V-BELT»(ref-208375-S02582614092005120700000) .

1. Check the sprocket teeth for abnormal wear and scratches.
2. Make sure there is no free play between sprocket and key.
3. Check the crankshaft sprocket notch used for sensor for damage and contamination of foreign matter.

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1. Remove the V-belt. Refer to «V-BELT»(ref-208375-S02582614092005120700000) .
2. Remove the crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208375-S06250155732005120700000) .
3. Remove the timing belt cover. Refer to «TIMING BELT COVER»(ref-208375-S14270702252005120700000) .
4. Remove the timing belt assembly. Refer to «TIMING BELT ASSEMBLY»(ref-208375-S14337869732005120700000) .
5. Remove the camshaft sprocket. Refer to «CRANKSHAFT PULLEY»(ref-208375-S06250155732005120700000) .
6. Remove the crankshaft sprocket. Refer to «CRANKSHAFT SPROCKET»(ref-208375-S38349563822005120700000) .
7. Disconnect the variable valve timing solenoid valve assembly connector.
8. Remove the tensioner bracket.
9. Remove the timing belt cover No. 2 (LH).
10. Remove the timing belt cover No. 2 (RH).
11. Remove the spark plug cord.
12. Remove the oil level gauge guide. (LH side)
13. Remove the rocker cover and gasket.
14. Remove the oil pipe.
15. Loosen the variable valve timing solenoid valve assembly and intake camshaft cap bolts equally, a little at a time in alphabetical sequence shown in the figure.
16. Remove the variable valve timing solenoid valve assembly, intake camshaft cap, and camshaft.
17. Loosen the exhaust camshaft cap bolts equally, a little at a time in alphabetical sequence shown in the figure.
18. Remove the exhaust camshaft cap and camshaft. NOTE: Arrange the camshaft caps in order so that they can be installed in their original positions.
19. Similarly, remove the camshafts (RH) and related parts.

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1. Camshaft installation: Apply engine oil to cylinder head at camshaft bearing location before installing the camshaft. Install the camshaft so that each valve is close to or in contact with "base circle" of cam lobe. NOTE: When the camshafts are positioned as shown in the figure, camshafts need to be rotated at a minimum to align with the timing belt during installation. Camshaft (RH) need not be rotated when set at position shown in the figure. Intake camshaft (LH): Rotate 80° clockwise. Exhaust camshaft (LH): Rotate 45° counterclockwise.
2. Camshaft cap and variable valve timing solenoid valve assembly installation: Apply fluid packing sparingly to cap mating surface. NOTE: Do not apply fluid packing excessively. Failure to do so may cause excess packing to come out and flow toward the oil seal, resulting in oil leaks. Fluid packing: Part No. 004403007 THREE BOND 1215 or equivalent Apply engine oil to cap bearing surface and install the cap on camshaft as shown by identification mark (A). Gradually tighten the camshaft cap and oil control valve assembly in at least two stages in alphabetical sequence shown in the figure, and then tighten to specified torque. Tightening torque: T1: 10 N.m (1.0 kgf-m, 7 ft-lb) T2: 20 N.m (2.0 kgf-m, 14.5 ft-lb) Similarly, tighten cap on the exhaust side. After tightening cap, ensure the camshaft rotates only slightly while holding it at "base" circle. Tightening torque: T1: 10 N.m (1.0 kgf-m, 7 ft-lb) T2: 20 N.m (2.0 kgf-m, 14.5 ft-lb)
3. Camshaft oil seal installation: Apply grease to new oil seal lips and press onto front end of camshaft by using ST1 and ST2. NOTE: Use a new oil seal. ST1 499587600 OIL SEAL GUIDE ST2 499597200 OIL SEAL GUIDE
4. Rocker cover installation: Install the gasket on rocker cover. Install the peripheral gasket and ignition coil gasket. Apply fluid packing to the specified point of cylinder head. Fluid packing: Part No. 004403007 THREE BOND 1215 or equivalent Install the rocker cover on cylinder head. Ensure the gasket is properly positioned during installation. Tighten the rocker cover tightening bolt in alphabetical sequence shown in the figure, and then tighten to specified torque. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
5. Install the oil pipe. Tightening torque: 29 N.m (3.0 kgf-m, 21.4 ft-lb)
6. Connect the variable valve timing solenoid valve connector.
7. Install the spark plug cord.
8. Similarly, install the parts on right-hand side.
9. Install the timing belt cover No. 2 (RH). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
10. Install the timing belt cover No. 2 (LH). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
11. Install the tensioner bracket. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb)
12. Install the crankshaft sprocket. Refer to «CRANKSHAFT SPROCKET»(ref-208375-S38349563822005120700000) .
13. Install the camshaft sprockets. Refer to «CAMSHAFT SPROCKET»(ref-208375-S14426545902005120700000) .
14. Install the timing belt assembly. Refer to «INSTALLATION»(ref-208375-S23626259932005120700000) , Timing Belt Assembly.
15. Install the timing belt cover. Refer to «TIMING BELT COVER»(ref-208375-S14270702252005120700000) .
16. Install the crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208375-S06250155732005120700000) .
17. Install the V-belt. Refer to «V-BELT»(ref-208375-S02582614092005120700000) .

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1. Measure the bend, and repair or replace if necessary. Limit: 0.020 mm (0.0008 in)
2. Check the journal for damage and wear. Replace if faulty.
3. Measure the outside diameter of camshaft journal. If the journal diameter is not as specified, check the oil clearance.
4. Measurement of the camshaft journal oil clearance: Clean the bearing caps and camshaft journals. Place the camshafts on cylinder head. (Without installing the valve rocker.) Place a plastigauge across each of the camshaft journals. Gradually tighten the cap in at least two stages in alphabetical sequence shown in the figure, and then tighten to specified torque. Do not turn the camshaft. Tightening torque: T1: 10 N.m (1.0 kgf-m, 7.2 ft-lb) T2: 20 N.m (2.0 kgf-m, 14.5 ft-lb) Remove the bearing caps. Measure the widest point of plastigauge on each journal. If the oil clearance exceeds the limit, replace the camshaft. If necessary, replace the camshaft caps and cylinder head as a set. Standard: 0.037 - 0.072 mm (0.0015 - 0.0028 in) Limit: 0.10 mm (0.0039 in) Completely remove the plastigauge.
5. Check the cam face condition; remove the minor faults by grinding with oil stone. Measure the cam height H, replace if the limit has been exceeded. Cam height: H Standard: Intake: 46.55 - 46.65 mm (1.833 - 1.837 in) Exhaust: 46.75 - 46.85 mm (1.841 - 1.844 in) Limit: Intake: 46.45 mm (1.829 in) Exhaust: 46.65 mm (1.837 in) Cam base circle diameter A: 37.0 mm (1.457 in)
6. Measure the thrust clearance of camshaft with dial gauge. If the clearance exceeds the limit, replace the caps and cylinder head as a set. If necessary, replace the camshaft. Standard: 0.068 - 0.116 mm (0.0027 - 0.0046 in) Limit: 0.14 mm (0.0055 in)

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1. Remove the V-belt. Refer to «V-BELT»(ref-208375-S02582614092005120700000) .
2. Remove the crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208375-S06250155732005120700000) .
3. Remove the timing belt cover. Refer to «TIMING BELT COVER»(ref-208375-S14270702252005120700000) .
4. Remove the timing belt assembly. Refer to «TIMING BELT ASSEMBLY»(ref-208375-S14337869732005120700000) .
5. Remove the camshaft sprocket. Refer to «CAMSHAFT SPROCKET»(ref-208375-S14426545902005120700000) .
6. Remove the intake manifold. Refer to «REMOVAL»(ref-208372-S04765423592005120700000) , Intake Manifold.
7. Remove the bolt which installs the A/C compressor bracket on cylinder head.
8. Remove the camshaft. Refer to «REMOVAL»(ref-208375-S09963510432005120700000) , Camshaft.
9. Remove the cylinder head bolts in alphabetical sequence shown in the figure. Leave bolts (A) and (D) engaged by three or four threads to prevent the cylinder head from falling.
10. While tapping the cylinder head with a plastic hammer, separate it from cylinder block. Remove the bolts (A) and (D) to remove cylinder head.
11. Remove the cylinder head gasket. NOTE: Do not scratch the mating surface of cylinder head and cylinder block.
12. Similarly, remove the cylinder head (RH).

Scheme 482

1. Install the cylinder head and gaskets on cylinder block. NOTE: Use new cylinder head gaskets. Be careful not to scratch the mating surface of cylinder head and cylinder block.
2. Tighten the cylinder head bolts. Apply a coat of engine oil to the washers and bolt threads. Tighten all bolts to 29 N.m (3.0 kgf-m, 22 ft-lb) in alphabetical sequence. Tighten all bolts to 69 N.m (7.0 kgf-m, 51 ft-lb) in alphabetical sequence again. Back off all bolts by 180° first; back them off by 180° again in reverse order of installation. Tighten all bolts to 49 N.m (5.0 kgf-m, 36 ft-lb) in alphabetical sequence. Tighten all bolts 80 to 90° in alphabetical sequence. Tighten all bolts by 40 to 45° in alphabetical sequence again. NOTE: Do not tighten the bolts by more than 45°. Further tighten all bolts (A) and (B) by 40 to 45°. NOTE: Ensure that the total "re-tightening angle" in the previous two steps do not exceed 90°.
3. Install the camshaft. Refer to «INSTALLATION»(ref-208375-S26193171142005120700000) , Camshaft.
4. Install the A/C compressor bracket on cylinder head.
5. Install the intake manifold. Refer to «INSTALLATION»(ref-208372-S38405989972005120700000) , Intake Manifold.
6. Install the camshaft sprocket. Refer to «CAMSHAFT SPROCKET»(ref-208375-S14426545902005120700000) .
7. Install the timing belt assembly. Refer to «INSTALLATION»(ref-208375-S23626259932005120700000) , Timing Belt Assembly.
8. Install the timing belt cover. Refer to «TIMING BELT COVER»(ref-208375-S14270702252005120700000) .
9. Install the crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208375-S06250155732005120700000) .
10. Install the V-belt. Refer to «V-BELT»(ref-208375-S02582614092005120700000) .

Note. "RANK" shown in the chart refers to the possibility of reason for the trouble in order ("Very often" to "Rarely")

A - Very often

B - Sometimes

C - Rarely

Scheme 483

Scheme 484

Scheme 485

Scheme 486

Scheme 487

Scheme 488

Note. When disconnecting the fuel injector connector, Malfunction Indicator Light illuminates and DTC is stored in ECM memory. Therefore, carry out the CLEAR MEMORY MODE. Refer to CLEAR MEMORY MODE and INSPECTION MODE. Refer to INSPECTION MODE after connecting the fuel injector connector.