Engine Mechanical (H4DOTC): Other Subaru Baja I

CAUTION

1. Wear working clothing, including a cap, protective goggles, and protective shoes during operation.
2. Remove contamination including dirt and corrosion before removal, installation or disassembly.
3. Keep the disassembled parts in order and protect them from dust or dirt.
4. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement.
5. Be careful not to burn your hands, because each part in the vehicle is hot after running.
6. Be sure to tighten fasteners including bolts and nuts to the specified torque.
7. Place shop jacks or safety stands at the specified points.
8. Before disconnecting electrical connectors of sensors or units, be sure to disconnect the ground cable from battery.
9. All parts should be thoroughly cleaned, paying special attention to the engine oil passages, pistons and bearings.
10. Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to assembly.
11. Be careful not to let oil, grease or coolant contact the timing belt, clutch disc and flywheel.
12. All removed parts, if to be reused, should be reinstalled in the original positions and directions.
13. Bolts, nuts and washers should be replaced with new ones as required.
14. Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks.
15. Remove or install the engine in an area where chain hoists, lifting devices, etc. are available for ready use.
16. Be sure not to damage coated surfaces of body panels with tools or stain seats and windows with coolant or oil. Place a cover over fenders, as required, for protection.
17. Prior to starting work, prepare the following: Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc.
18. Lift-up or lower the vehicle when necessary. Make sure to support the correct positions.

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PROCEDURE

It is possible to conduct the following service procedures with engine on the vehicle, however, the procedures described in this section are based on the condition that the engine is removed from the vehicle.

1. V-belt
2. Timing Belt
3. Camshaft
4. Cylinder Head

USING SUBARU SELECT MONITOR

1. Before checking the idle speed, check the following: Ensure the air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and that the hoses are connected properly. Ensure the malfunction indicator light does not illuminate.
2. Warm-up the engine.
3. Stop the engine, and then turn the ignition switch to OFF.
4. Insert the cartridge to SUBARU SELECT MONITOR.
5. Connect the SUBARU SELECT MONITOR to data link connector.
6. Turn the ignition switch to ON, and SUBARU SELECT MONITOR switch to ON.
7. Select the {2. Each System Check} in Main Menu.
8. Select the {Engine Control System} in Selection Menu.
9. Select the {1. Current Data Display & Save} in Engine Control System Diagnosis.
10. Select the {1.12 Data Display} in Data Display Menu.
11. Start the engine, and then read the engine idle speed.
12. Check the idle speed when unloaded. (With headlights, heater fan, rear defroster, radiator fan, air conditioning, etc. OFF) Idle speed [No load and gears in neutral]: 700+/-100 RPM
13. Check the idle speed when loaded. (Turn the air conditioning switch to "ON" and operate the compressor for at least 1 minute before measurement.)

Idle speed [A/C "ON", no load and gears in neutral]

1. A/C refrigerant pressure is low MT: 725+/-100 RPM AT: 750+/-100 RPM
2. A/C refrigerant pressure is high MT: 800+/-100 RPM AT: 825+/-100 RPM

Note. As idle speed is controlled by the automatic adjustment type, it can not be adjusted manually. If the idle speed is out of specifications, refer to General On-board Diagnosis Table under "Engine Control System". Refer to GENERAL DIAGNOSTIC TABLE .

1. Before checking the ignition timing speed, check the following: Ensure the air cleaner element is free from clogging, spark plugs are in good condition, and that hoses are connected properly. Ensure the malfunction indicator light does not illuminate.
2. Warm-up the engine.
3. Stop the engine, and then turn the ignition switch to OFF.
4. Insert the cartridge to SUBARU SELECT MONITOR.
5. Connect the SUBARU SELECT MONITOR to data link connector.
6. Turn the ignition switch to ON, and SUBARU SELECT MONITOR switch to ON.
7. Select the {2. Each System Check} in Main Menu.
8. Select the {Engine Control System} in Selection Menu.
9. Select the {1. Current Data Display & Save} in Engine Control System Diagnosis.
10. Select the {1.12 Data Display} in Data Display Menu.
11. Start the engine and check the ignition timing at idle speed.

Ignition timing [BTDC/RPM]

MT model

13°+/-10°

AT model

17°+/-10°

If the timing is not correct, check the ignition control system. Refer to Engine Control System. Refer to BASIC DIAGNOSTIC PROCEDURE .

FRONT SIDE BELT

1. Install the belt (C), and tighten the slider bolt so as to obtain the specified belt tension. Refer to «INSPECTION»(ref-208375-S35298240502005120700000) .
2. Tighten the lock bolt (A).
3. Tighten the slider bolt (B).

Tightening torque

Lock bolt through bolt

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

Slider bolt

8 N.m (0.8 kgf-m, 5.5 ft-lb)

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REAR SIDE BELT

1. Install the belt, and tighten the slider bolt (B) so as to obtain the specified belt tension. Refer to «INSPECTION»(ref-208375-S35298240502005120700000) .
2. Tighten the lock nut (A).

Tightening torque

Lock nut (A)

22.6 N.m (2.3 kgf-m, 16.6 ft-lb)

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TIMING BELT

1. Check the timing belt teeth for breaks, cracks, and wear. If any fault is found, replace the belt.
2. Check the condition of back side of belt; if any crack is found, replace the belt.

Note. Be careful not to let oil, grease or coolant contact the belt. Remove quickly and thoroughly if this happens. Do not bend the belt sharply.

Bending radius: h

60 mm (2.36 in) or more

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AUTOMATIC BELT TENSION ADJUSTER

1. Visually check the oil seals for leaks, and rod ends for abnormal wear or scratches. If necessary, replace the automatic belt tension adjuster assembly. NOTE: Slight traces of oil at rod's oil seal does not indicate a problem.
2. Check that the adjuster rod does not move when a pressure of 294 N (30 kgf, 66 lb) is applied to it. This is to check adjuster rod stiffness.
3. If the adjuster rod is not stiff and moves freely when applying 294 N (30 kgf, 66 lb), check it using the following procedures: Slowly press the adjuster rod down to the end surface of the cylinder. Repeat this motion 2 or 3 times. With the adjuster rod moved all the way up, apply a pressure of 294 N (30 kgf, 66 lb) to it Check the adjuster rod stiffness. If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new one. 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. 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 the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder.
4. Measure the extension of rod beyond the body. If it is not within specifications, replace with a new one.

Rod extension: H

5.7+/-0.5 mm (0.224+/-0.020 in)

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BELT TENSION PULLEY

1. Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace the belt tension pulley if faulty.
2. Check the belt tension pulley for smooth rotation. Replace if noise or excessive play is noted.
3. Check the belt tension pulley for grease leakage.

BELT IDLER

1. Check the belt idler for smooth rotation. Replace if noise or excessive play is noted.
2. Check the outer contacting surfaces of idler pulley for abnormal wear and scratches.
3. Check the belt idler for grease leakage.

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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 sprockets. To lock the camshaft, use ST. ST 499207400 CAMSHAFT SPROCKET WRENCH 499977500 CAMSHAFT SPROCKET WRENCH

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1. Install the camshaft sprocket. To lock the camshaft, use ST. NOTE: Do not confuse camshaft sprockets (RH) and (LH) during installation. ST 499207400 CAMSHAFT SPROCKET WRENCH Tightening torque: 98 N.m (10 kgf-m, 72.4 ft-lb) ST 499977500 CAMSHAFT SPROCKET WRENCH Tightening torque: 29.5 N.m (3.0 kgf-m, 21.8 ft-lb), and then tighten 45° furthermore
2. Install the timing belt assembly. Refer to «INSTALLATION»(ref-208375-S23626259932005120700000) , Timing Belt Assembly.
3. Install the timing belt cover. Refer to «TIMING BELT COVER»(ref-208375-S14270702252005120700000) .
4. Install the crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208375-S06250155732005120700000) .
5. Install the V-belt. Refer to «V-BELT»(ref-208375-S02582614092005120700000) .

CYLINDER HEAD

1. Make sure that no crack or other damage exists. In addition to visual inspection, inspect the important areas by means of red check.
2. Measure the warping of the cylinder head surface that mates with crankcase by using a straight edge (A) and thickness gauge (B). If the warping exceeds 0.05 mm (0.0020 in), regrind the surface with a surface grinder.

Warping limit

0.05 mm (0.0020 in)

Grinding limit

0.3 mm (0.012 in)

Standard height of cylinder head

127.5 mm (5.02 in)

Note. Uneven torque for the cylinder head nuts can cause warping. When reassembling, pay special attention to the torque so as to tighten evenly.

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VALVE SEAT

Inspect the intake and exhaust valve seats, and then correct the contact surfaces with valve seat cutter if they are defective or when valve guides are replaced.

Valve seat width: W

Intake

Standard 1.0 mm (0.039 in)

Limit 1.7 mm (0.067 in)

Exhaust

Standard 1.5 mm (0.059 in)

Limit 2.2 mm (0.087 in)

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1. Check the clearance between valve guide and stem. The clearance can be checked by measuring the outside diameter of valve stem and the inside diameter of valve guide with outside and inside micrometers respectively. Clearance between the valve guide and valve stem: Standard Intake 0.030 - 0.057 mm (0.0012 - 0.0022 in) Exhaust 0.040 - 0.067 mm (0.0016 - 0.0026 in) Limit 0.15 mm (0.0059 in)
2. If the clearance between valve guide and stem exceeds the limit, replace the valve guide or valve itself whichever shows greater amount of wear. See the following procedure for valve guide replacement. Valve guide inner diameter: 6.000 - 6.012 mm (0.2362 - 0.2367 in) Valve stem outer diameters: Intake 5.955 - 5.970 mm (0.2344 - 0.2350 in) Exhaust 5.945 - 5.960 mm (0.2341 - 0.2346 in) Place the cylinder head on ST1 with the combustion chamber upward so that valve guides enter the holes in ST1. Insert the ST2 into valve guide and press it down to remove the valve guide. ST1 498267600 CYLINDER HEAD TABLE ST2 499767200 VALVE GUIDE REMOVER
3. Turn the cylinder head upside down and place ST as shown in the figure. ST 18251AA020 VALVE GUIDE ADJUSTER
4. Before installing a new valve guide, make sure that neither scratches nor damages exist on the inside surface of the valve guide holes in cylinder head.
5. Put a new valve guide, coated with sufficient oil, in cylinder, and insert ST1 into valve guide. Press in until the valve guide upper end is flush with the upper surface of ST2. ST1 499767200 VALVE GUIDE REMOVER ST2 18251AA020 VALVE GUIDE ADJUSTER
6. Check the valve guide protrusion. Valve guide protrusion: L 15.8 - 16.2 mm (0.622 - 0.638 in)
7. Ream the inside of valve guide with ST. Gently rotate the reamer clockwise while pressing it lightly into the valve guide, and return it also rotating clockwise. After reaming, clean the valve guide to remove chips. ST 499767400 VALVE GUIDE REAMER NOTE: Apply engine oil to the reamer when reaming. If the inner surface of the valve guide is torn, the edge of the reamer should be slightly ground with an oil stone. If the inner surface of the valve guide becomes lustrous and the reamer does not chip, use a new reamer or remedy the reamer.
8. Recheck the contact condition between valve and valve seat after replacing the valve guide.

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1. Inspect the flange and stem of valve, and replace if damaged, worn, or deformed, or if "H" is less than the specified limit. H: Intake (A) Standard 1.2 mm (0.047 in) Limit 0.8 mm (0.031 in) Exhaust (B) Standard 1.5 mm (0.059 in) Limit 0.8 mm (0.031 in) Valve overall length: Intake (A) 104.4 mm (4.110 in) Exhaust (B) 104.65 mm (4.120 in)
2. Put a small amount of grinding compound on the seat surface and lap the valve and seat surface. Install a new intake valve oil seal after lapping.

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1. Check the valve springs for damage, free length, and tension. Replace the valve spring if it is not within specifications presented in the table.
2. To measure the squareness of valve spring, stand the spring on a surface plate and measure its deflection at the top using a try square.

INTAKE AND EXHAUST VALVE OIL SEAL

Replace the oil seal with a new one, if the lip is damaged or spring out of place, or when the surfaces of intake valve and valve seat are reconditioned or intake valve guide is replaced.

1. Place the cylinder head on ST1.
2. Press in the oil seal to the specified dimension indicated in the figure by using ST2.

ST1 498267600 CYLINDER HEAD TABLE

ST2 498857100 VALVE OIL SEAL GUIDE

Note. Apply engine oil to oil seal before press-fit. Differentiate between the intake valve oil seal and exhaust valve oil seal by noting their difference in color.

Color of rubber part

Intake [Black] Exhaust [Brown]

Color of spring part

Intake [White] Exhaust [White]

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1. Visually check the valve lifter.
2. Measure the outer diameter of valve lifter. Outer diameter: 34.959 - 34.975 mm (1.3763 - 1.3770 in)
3. Measure the inner diameter of valve lifter mating part on cylinder head.

Inner diameter

34.994 - 35.016 mm (1.3777 - 1.3786 in)

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Note. If difference between outer diameter of valve lifter and inner diameter of valve lifter mating part is over the limit, replace the cylinder head.

Standard

0.019 - 0.057 mm (0.0007 - 0.0022 in)

Limit

0.100 mm (0.0039 in)

DISPOSAL

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1. If the valve is damaged, remove the valve and neutralize it by immersing it in water, and dispose of it in the same way that general steel materials are disposed of. The disposal method is described in the following. Wearing rubber gloves, remove the damaged valve from the cylinder head. Prepare a large receptacle (bucket or other container) in a well ventilated location, and fill the receptacle with water (at least 10 liters). Immerse the damaged valve in the receptacle. CAUTION: A severe reaction may occur, so stand at least 2 - 3 m from the receptacle. Because the reaction will produce hydrogen gas, moreover, keep the receptacle away from sparks or flames. Once the reaction is completed (about 4 - 5 hours have elapsed), carefully remove the valve using large pincers so that the reaction liquid does not contact your skin, and dispose of it with other parts that are being disposed of. The reaction liquid is a strong alkaline solution, so it must be disposed of in accordance with local regulations. CAUTION: Make sure the reaction liquid does not contact your skin. If contact with skin occurs, immediately wash the affected area with large quantities of water.

CYLINDER BLOCK

1. Visually check for cracks and damage. Especially, inspect the important parts by means of red lead check.
2. Check the oil passages for clogging.
3. Inspect the crankcase surface that mates with cylinder head for warping by using a straight edge, and correct by grinding if necessary. Warping limit: 0.05 mm (0.0020 in) Grinding limit: 0.1 mm (0.004 in) Standard height of cylinder block: 201.0 mm (7.91 in)

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1. The cylinder bore size is stamped on cylinder block's front upper surface. NOTE: Measurement should be performed at a temperature of 20°C (68°F). NOTE: Standard sized pistons are classified into two grades, "A" and "B". These grades should be used as a guide line in selecting a standard piston. Standard diameter: A: 99.505 - 99.515 mm (3.9175 - 3.9179 in) B: 99.495 - 99.505 mm (3.9171 - 3.9175 in)
2. How to measure the inner diameter of each cylinder: Measure the inner diameter of each cylinder in bore the thrust and piston pin directions at the heights shown in the figure, using a cylinder bore gauge. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Taper: Standard 0.015 mm (0.0006 in) Limit 0.050 mm (0.0020 in) Out-of-roundness: Standard 0.010 mm (0.0004 in) Limit 0.050 mm (0.0020 in)
3. When the piston is to be replaced due to general or cylinder wear, determine a suitable sized piston by measuring the piston clearance.
4. How to measure the outer diameter of each piston: Measure the outer diameter of each piston at the height shown in the figure. (Thrust direction) NOTE: Measurement should be performed at a temperature of 20°C (68°F). Piston grade point H: 38.2 mm (1.50 in) Piston outer diameter: Standard A: 99.505 - 99.515 mm (3.9175 - 3.9179 in) B: 99.495 - 99.505 mm (3.9171 - 3.9175 in) 0.25 mm (0.0098 in) oversize 99.745 - 99.765 mm (3.9270 - 3.9278 in) 0.50 mm (0.0197 in) oversize 99.995 - 100.015 mm (3.9368 - 3.9376 in)
5. Calculate the clearance between cylinder and piston. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Cylinder to piston clearance at 20°C (68°F): Standard -0.010 - 0.010 mm (-0.0004 - 0.0004 in) Limit 0.030 mm (0.0012 in)
6. Boring and honing: If the value of taper, out-of-roundness, or cylinder-to-piston clearance measured exceeds the specified limit or if there is any damage on the cylinder wall, reboring it to use an oversize piston. CAUTION: When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and use oversize pistons. Do not perform boring on one cylinder only, nor use an oversize piston for one cylinder only. If the cylinder inner diameter exceeds the limit after boring and honing, replace the crank-case. NOTE: Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, pay attention to this when measuring the cylinder diameter. Limit of cylinder enlarging (boring): 0.5 mm (0.020 in)

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1. Check the pistons and piston pins for damage, cracks, and wear and the piston ring grooves for wear and damage. Replace if defective.
2. Measure the piston-to-cylinder clearance at each cylinder. Refer to «CYLINDER AND PISTON»(ref-208375-S05684574442005120700000) . If any of the clearances is not within specification, replace the piston or bore the cylinder to use an oversize piston.
3. Make sure that the piston pin can be inserted into the piston pin hole with a thumb at 20°C (68°F). Replace if defective. Standard clearance between piston pin and hole in piston: Standard 0.004 - 0.008 mm (0.0002 - 0.0003 in) Limit 0.020 mm (0.0008 in)
4. Check the circlip installation groove on piston for burr (A). If necessary, remove the burr from groove so that the piston pin can lightly move.
5. Check the piston pin circlip for distortion, cracks and wear.

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1. If the piston ring is broken, damaged, or worn, on if its tension is insufficient, or when the piston is replaced, replace the piston ring with a new one of the same size as the piston. NOTE: Marks are shown on the end of top and second rings. When installing the rings to piston, face this mark upward. Oil ring consists of upper rail, expander and lower rail. When installing on piston, be careful of each rail's direction.
2. Squarely place the piston ring and oil ring in cylinder, and then measure the piston ring gap with a thickness gauge.
3. Measure the clearance between piston ring and piston ring groove with a thickness gauge.

Note. Before measuring the clearance, clean the piston ring groove and piston ring.

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1. Replace the connecting rod, if the large or small end thrust surface is damaged.
2. Check for bend or twist using a connecting rod aligner. Replace the connecting rod if the bend or twist exceeds the limit. Limit of bend or twist per 100 mm (3.94 in) in length: 0.10 mm (0.0039 in)
3. Install the connecting rod fitted with bearing to crankshaft, and then measure the side clearance (thrust clearance). Replace the connecting rod if the side clearance exceeds the specified limit. Connecting rod side clearance: Standard 0.070 - 0.330 mm (0.0028 - 0.0130 in) Limit 0.40 mm (0.016 in)
4. Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc.
5. Measure the oil clearance on individual connecting rod bearings by means of plastigauge. If any oil clearance is not within specification, replace the defective bearing with a new one of standard size or undersize as necessary. (See the table below.) Connecting rod oil clearance: Standard 0.017 - 0.045 mm (0.0007 - 0.0018 in) Limit 0.050 mm (0.0020 in)
6. Inspect the bushing at connecting rod small end, and replace if worn or damaged. Also measure the piston pin clearance at connecting rod small end. Clearance between piston pin and bushing: Standard 0 - 0.022 mm (0 - 0.0009 in) Limit 0.030 mm (0.0012 in)
7. Replacement procedure is as follows: Remove the bushing from connecting rod with ST and press. Press the bushing with ST after applying oil on the periphery of bushing. ST 499037100 CONNECTING ROD BUSHING REMOVER AND INSTALLER Make two 3 mm (0.12 in) holes in bushing. Ream the inside of bushing. After the completion of reaming, clean the bushing to remove chips.

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1. Clean the crankshaft completely and check for cracks by means of red lead check etc., and replace if defective.
2. Measure the crankshaft bend, and correct or replace if it exceeds the limit. NOTE: If a suitable V-block is not available, install the #1 and #5 crankshaft bearing on cylinder block, position the crankshaft on these bearings and measure the crankshaft bend using a dial gauge. Crankshaft bend limit: 0.035 mm (0.0014 in)
3. Inspect the crank journal and crank pin for wear. If they are not within the specifications, replace the bearing with a suitable (undersize) one, and then replace or recondition the crankshaft as necessary. When grinding the crank journal or crank pin, finish them to specified dimensions according to the undersize bearing to be used. Crank pin and crank journal: Out-of-roundness 0.005 mm (0.0002 in) or less Taper limit 0.07 mm (0.0028 in) Grinding limit 0.250 mm (0.0098 in)
4. Measure the thrust clearance of crankshaft at center bearing. If the clearance exceeds the limit, replace the bearing. Crankshaft side clearance: Standard 0.030 - 0.115 mm (0.0012 - 0.0045 in) Limit 0.25 mm (0.0098 in)
5. Inspect individual crankshaft bearings for signs of flaking, seizure, melting, and wear.
6. Measure the oil clearance on each crankshaft bearing by means of plastigauge. If the measurement is not within the specification, replace the defective bearing with an undersize one, and replace or recondition the crankshaft as necessary.