Engine Mechanical (H4DOTC): Removal & Installation Subaru Baja I

REMOVAL

1. Remove the engine assembly. Refer to «ENGINE ASSEMBLY»(ref-208375-S25781720942005120700000) .
2. Remove the engine mounting from engine assembly.

INSTALLATION

Install in the reverse order of removal.

Tightening torque

Engine mounting

35 N.m (3.6 kgf-m, 25.8 ft-lb)

Note. Before conducting this procedure, drain the engine oil completely if applicable.

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1. Remove the intake manifold. Refer to «REMOVAL»(ref-208372-S04765423592005120700000) , Intake Manifold.
2. Remove the V-belt. Refer to «V-BELT»(ref-208375-S02582614092005120700000) .
3. Remove the crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208375-S06250155732005120700000) .
4. Remove the timing belt cover. Refer to «TIMING BELT COVER»(ref-208375-S14270702252005120700000) .
5. Remove the timing belt assembly. Refer to «TIMING BELT ASSEMBLY»(ref-208375-S14337869732005120700000) .
6. Remove the camshaft sprocket. Refer to «CAMSHAFT SPROCKET»(ref-208375-S14426545902005120700000) .
7. Remove the crankshaft sprocket. Refer to «CRANKSHAFT SPROCKET»(ref-208375-S38349563822005120700000) .
8. Remove the generator and A/C compressor with their brackets.
9. Remove the cylinder head assembly. Refer to «CYLINDER HEAD ASSEMBLY»(ref-208375-S34017000572005120700000) .
10. Remove the clutch disc and cover. Refer to «REMOVAL»(ref-208403-S15898668002005120700000) , Clutch Disc and Cover.
11. Remove the flywheel. (MT model) Refer to «REMOVAL»(ref-208403-S15898668002005120700000) , Clutch Disc and Cover.
12. Remove drive plate. (AT model) Using ST, lock crankshaft. ST 498497100 CRANKSHAFT STOPPER
13. Remove the oil separator cover.
14. Remove the water by-pass pipe for heater.
15. Remove the oil filter. ST 18332AA000 OIL FILTER WRENCH (Outer diameter: 68 mm (2.68 in)) ST 18332AA010 OIL FILTER WRENCH (Outer diameter: 65 mm (2.56 in))
16. Remove the oil cooler.
17. Removal of oil pan: Turn the cylinder block with #2 and #4 piston sides facing upward. Remove the bolts which secure oil pan to cylinder block. Insert an oil pan cutter blade between cylinder block-to-oil pan clearance, and then remove the oil pan. Do not use a screwdriver or similar tool in place of oil pan cutter.
18. Remove the oil strainer stay.
19. Remove the oil strainer.
20. Remove the baffle plate.
21. Remove the water pipes.
22. Remove the water pump.
23. Remove the oil pump from cylinder block. Use a flat-bladed screwdriver as shown in the figure when removing the oil pump. NOTE: Be careful not to scratch the mating surface of cylinder block and oil pump.
24. Remove the service hole cover and service hole plugs using hexagon wrench [14 mm (0.55 in)].
25. Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, and then remove the piston circlip through service hole of #1 and #2 cylinders.
26. Draw out the piston pin from #1 and #2 pistons using ST. ST 499097700 PISTON PIN REMOVER NOTE: Be careful not to confuse the original combination of piston, piston pin and cylinder.
27. Similarly remove the piston pins from #3 and #4 pistons.
28. Remove the bolts which connect the cylinder block on the side of #2 and #4 cylinders.
29. Back off the bolts which connect the cylinder block on the side of #1 and #3 cylinders two or three turns.
30. Set up the cylinder block so that #1 and #3 cylinders are on the upper side, then remove the cylinder block connecting bolts.
31. Separate the cylinder blocks (LH) and (RH). NOTE: When separating the cylinder block, do not allow the connecting rod to fall and damage the cylinder block.
32. Remove the rear oil seal.
33. Remove the crankshaft together with connecting rod.
34. Remove the crankshaft bearings from cylinder block using a hammer handle. NOTE: Do not confuse the combination of crankshaft bearings. Press the bearing at the end opposite to locking lip.
35. Draw out each piston from cylinder block using a wooden bar or hammer handle. NOTE: Do not confuse the combination of piston and cylinder.

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1. Remove oil in the mating surface of bearing and cylinder block before installation. Also apply a coat of engine oil to crankshaft pins.
2. Position the crankshaft on #2 and #4 cylinder block.
3. Apply fluid packing to the mating surface of #1 and #3 cylinder block, and position it on #2 and #4 cylinder block. Fluid packing: Part No. 004403007 THREE BOND 1215 or equivalent NOTE: Do not allow fluid packing to jut into O-ring grooves, oil passages, bearing grooves, etc.
4. Apply engine oil to washers and thread of bolts.
5. Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure. (LH side) Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb)
6. Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure. (RH side) Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb)
7. Further tighten the LH side bolts (A - D) in alphabetical sequence. Tightening torque: (A), (C): 20 N.m (2.0 kgf-m, 14.8 ft-lb) (B), (D): 15 N.m (1.5 kgf-m, 10.8 ft-lb)
8. Further tighten the RH side bolts (E - J) in alphabetical sequence. Tightening torque: (E), (F), (G), (I): 20 N.m (2.0 kgf-m, 14.8 ft-lb) (H), (J): 18 N.m (1.8 kgf-m, 13.3 ft-lb)
9. Further tighten the LH side bolts (A - D) by 90° in alphabetical sequence.
10. Further tighten the RH side bolts (E - J) by 90° in alphabetical sequence.
11. Tighten the 8 mm and 6 mm cylinder block connecting bolts in alphabetical sequence shown in the figure. Tightening torque: (A) - (G): 25 N.m (2.5 kgf-m, 18.1 ft-lb) (H): 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
12. Install the rear oil seal using ST1 and ST2. ST1 499597100 CRANKSHAFT OIL SEAL GUIDE ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER
13. Position the top ring gap at (A) or (B) in the figure.
14. Position the second ring gap at 180° on the reverse side for the top ring gap.
15. Position the upper rail gap at (C) in the figure.
16. Align upper rail spin stopper (D) with piston side surface hole (E).
17. Position the expander gap at (F) in the figure.
18. Position the lower rail gap at (G) in the figure. NOTE: Ensure ring gaps do not face the same direction. Ensure ring gaps are not within the piston skirt area.
19. Install the circlip. Install the circlips in piston holes located opposite of service holes in cylinder block, when positioning all pistons in the corresponding cylinders. NOTE: Use new circlips.
20. Installing the piston: Turn the cylinder block so that #1 and #2 cylinders face upward. Using the ST1, turn the crankshaft so that #1 and #2 connecting rods are set at bottom dead center. ST1 499987500 CRANKSHAFT SOCKET Apply a coat of engine oil to the pistons and cylinders and insert pistons in their cylinders using ST2. ST2 498747300 PISTON GUIDE NOTE: Piston front mark faces towards the front of the engine.
21. Installing piston pin: Apply a coat of engine oil to ST3, and then insert the ST3 into service hole to align piston pin hole with connecting rod small end. ST3 499017100 PISTON PIN GUIDE Apply a coat of engine oil to the piston pin and insert piston pin into piston and connecting rod through service hole. Using the ST, install the circlip. NOTE: Use new circlips. Apply fluid packing around the service hole plug. Fluid packing: Part No. 004403007 THREE BOND 1215 or equivalent Install the service hole plug and gasket. NOTE: Use a new gasket. Turn the cylinder block so that #3 and #4 cylinders face upward. Using the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
22. Install the water pipe.
23. Install the baffle plate. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
24. Install the oil strainer and O-ring Tightening torque: 10 N.m (1.0 kgf-m, 7 ft-lb)
25. Install the oil strainer stay.
26. Apply fluid packing to the matching surfaces, and then install the oil pan. Fluid packing: Part No. 004403012 THREE BOND 1207C or equivalent Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
27. Apply fluid packing to the matching surfaces, and then install the oil separator cover. Fluid packing: Part No. 004403007 THREE BOND 1215 or equivalent Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
28. Install the flywheel. Refer to «INSTALLATION»(ref-208403-S07146240122005120700000) , Clutch Disc and Cover.
29. Install the clutch disc and cover. Refer to «REMOVAL»(ref-208403-S15898668002005120700000) , Clutch Disc and Cover.
30. Installation of oil pump: Discard the front oil seal after removal. Replace with a new one using the ST. ST 499587100 OIL SEAL INSTALLER Apply fluid packing to the matching surface of oil pump. Fluid packing: Part No. 004403007 THREE BOND 1215 or equivalent Apply a coat of engine oil to the inside of the oil seal. Install the oil pump on cylinder block. Be careful not to damage the oil seal during installation. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) NOTE: Do not forget to install the O-ring and seal when installing the oil pump. Align the flat surface of oil pump's inner rotor with crankshaft before installation.
31. Install the water pump and gasket. Tightening torque: First; 12 N.m (1.2 kgf-m, 8.7 ft-lb) Second; 12 N.m (1.2 kgf-m, 8.7 ft-lb) NOTE: Be sure to use a new gasket. When installing the water pump, tighten the bolts in two stages in alphabetical sequence as shown in the figure.
32. Install the water by-pass pipe for heater.
33. Install the oil cooler. Tightening torque: T1: 45 N.m (4.6 kgf-m, 33 ft-lb) T2: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) T3: 54 N.m (5.3 kgf-m, 39 ft-lb)
34. Install the oil filter using ST. ST 18332AA000 OIL FILTER WRENCH (Outer diameter: 68 mm) ST 18332AA010 OIL FILTER WRENCH (Outer diameter: 65 mm)
35. Install the water by-pass pipe between oil cooler and water pump.
36. Install the water pipe. NOTE: Always use a new O-ring.
37. Install the cylinder head assembly. Refer to «CYLINDER HEAD ASSEMBLY»(ref-208375-S34017000572005120700000) .
38. Install the oil level gauge guide and tighten the attaching bolt (LH side).
39. Install the rocker cover.
40. Install the crankshaft sprocket. Refer to «CRANKSHAFT SPROCKET»(ref-208375-S38349563822005120700000) .
41. Install the camshaft sprocket. Refer to «CAMSHAFT SPROCKET»(ref-208375-S14426545902005120700000) .
42. Install the timing belt assembly. Refer to «INSTALLATION»(ref-208375-S23626259932005120700000) , Timing Belt Assembly.
43. Install the timing belt cover. Refer to «TIMING BELT COVER»(ref-208375-S14270702252005120700000) .
44. Install the crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-208375-S06250155732005120700000) .
45. Install the generator and A/C compressor brackets on cylinder head.
46. Install the V-belt. Refer to «V-BELT»(ref-208375-S02582614092005120700000) .
47. Install the intake manifold. Refer to «INSTALLATION»(ref-208372-S38405989972005120700000) , Intake Manifold.

Scheme 527

1. Remove the connecting rod cap.
2. Remove the connecting rod bearing. NOTE: Arrange the removed connecting rod, connecting rod cap and bearing in order to prevent confusion.
3. Remove the piston rings using the piston ring expander.
4. Remove the oil ring by hand. NOTE: Arrange the removed piston rings in proper order to prevent confusion.
5. Remove the circlip.

Scheme 528

1. Apply oil to the surfaces of the connecting rod bearings. Install the connecting rod bearings on connecting rods and connecting rod caps.
2. Install the connecting rod on crankshaft. NOTE: Position each connecting rod with the side marked facing forward.
3. Install the connecting rod cap with connecting rod nut. Ensure the arrow on connecting rod cap faces the front during installation. NOTE: Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching number. When tightening the connecting rod nuts, apply oil on the threads.
4. Install the oil ring spacer, upper rail and lower rail in this order by hand. Then install the second ring and top ring with a piston ring expander.