Engine Mechanical (H4DOTC): Diagnosis Subaru Forester SG рестайлинг

INSPECTION

Scheme 307

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. RELEASING OF FUEL PRESSURE PROCEDURE, Fuel.>
4. Remove all the spark plugs. REMOVAL Spark Plug.>
5. Fully open the throttle valve.
6. Check the starter motor for satisfactory performance and operation.
7. Hold the compression gauge tightly against the 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 the starter motor, and read the maximum value on the gauge when the pointer is steady. see scheme 7: Connecting Compression Gauge Into Cylinder Head Spark Plug Hole
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)

Service limit: 882 kPa (9.0 kgf/cm 2 , 128 psi)

Difference between cylinders: 49 kPa (0.5 kgf/cm 2 , 7 psi), or less

Scheme 308

1. Before checking the idle speed, check the following item: Check the air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and hoses are connected properly. Check the malfunction indicator light does not illuminate.
2. Warm-up the engine.
3. Stop the engine, and turn the ignition switch to OFF.
4. Insert the cartridge to Subaru Select Monitor.
5. Connect the Subaru Select Monitor to data link connector. see scheme 8: Locating Data Link Connector
6. Turn the ignition switch to ON and Subaru Select Monitor to ON.
7. Select {Each System Check} in Main Menu.
8. Select {Engine Control System} in Selection Menu.
9. Select {Current Data Display & Save} in Engine Control System Diagnosis.
10. Select {Data Display} in Data Display Menu.
11. Start the engine, and read the engine idle speed.
12. Check the idle speed when no-loaded. (Headlight, heater fan, rear defroster, radiator fan, A/C, etc. are 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 one minute before measurement.)

Idle speed [A/C "ON" and gears in neutral]

When A/C refrigerant pressure is low.

MT: 725±100 rpm

AT: 750±100 rpm

When A/C refrigerant pressure is low.

MT: 800±100 rpm

AT: 825±100 rpm

Note. Idle speed cannot be adjusted manually, because the idle speed is automatically adjusted. If the prescribed idle speed cannot be maintained, refer to General On-board Diagnosis Table under "Engine Control System". BASIC DIAGNOSTIC PROCEDURE .>

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

Ignition timing [BTDC/rpm]: 17°±10°/700

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

1. Remove the collector cover.
2. Warm-up the engine.
3. Disconnect the brake vacuum hose from the brake vacuum hose, and then install the vacuum gauge.
4. Keep the engine at idle speed and read the vacuum gauge indication.

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

Scheme 309

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

DIAGNOSIS OF ENGINE CONDITION BY MEASUREMENT OF MANIFOLD VACUUM

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1. Remove the collector cover.
2. Remove the oil pressure switch. REMOVAL Oil Pressure Switch.>
3. Connect the oil pressure gauge hose to cylinder block.
4. Connect the ground cable to battery. see scheme 11: Disconnecting Battery Ground Cable
5. Start the engine, and measure the oil pressure. see scheme 12: Measuring Oil Pressure Oil pressure: 98 kPa (1.0 kg/cm 2, 14 psi) or more at 600 rpm 294 kPa (3.0 kg/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. INSPECTION 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. INSPECTION Engine Lubrication System Trouble in General.> NOTE: The specified data is based on an engine oil temperature of 80°C (176°F).
6. After measuring the oil pressure, install the oil pressure switch. INSTALLATION 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. RELEASING OF FUEL PRESSURE PROCEDURE, Fuel.>
2. Disconnect the fuel delivery hose from fuel filter, and connect fuel pressure gauge. see scheme 13: Measuring Fuel Pressure
3. Connect the connector of fuel pump relay. see scheme 14: Locating Fuel Pump Relay Connector
4. Start the engine.
5. Measure the fuel pressure while disconnecting pressure regulator vacuum hose from intake manifold. Fuel pressure: Standard: 284 - 314 kPa (2.9 - 3.2 kgf/cm 2, 41 - 46 psi)
6. 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 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. see scheme 15: Disconnecting Battery Ground Cable
3. Remove the collector cover.
4. Remove the air intake duct. REMOVAL Air Intake Duct.>
5. Remove a bolt which secures timing belt cover (RH).
6. Lift-up the vehicle.
7. Remove the under cover.
8. Loosen the remaining bolts which secure timing belt cover (RH), then remove the timing belt cover.
9. Lower the vehicle.
10. When inspecting #1 and #3 cylinders: Pull out the engine harness connector with bracket from air cleaner upper cover. see scheme 16: Positioning Engine Harness Connector Remove the air cleaner case. REMOVAL Air Cleaner Case.> Disconnect the connector of ignition coil. Remove the ignition coil. Place a suitable container under the vehicle. Disconnect the PCV hose from rocker cover (RH). Remove the bolts, then remove the rocker cover (RH).
11. When inspecting #2 and #4 cylinders: Disconnect the battery cable, and then remove the battery and battery carrier. see scheme 17: Removing Battery Remove the bolt which holds the engine harness bracket on the body. see scheme 18: Locating Bolt Holding Engine Harness Bracket On Body Remove the secondary air pump. REMOVAL Secondary Air Pump. > Disconnect the connector of ignition coil. Remove the ignition coil. Place a suitable container under the vehicle. Disconnect the PCV hose from rocker cover (LH). Remove the bolts, then remove the rocker cover (LH).
12. Turn the crank pulley clockwise until arrow mark on the camshaft sprocket is set to position shown in the figure. NOTE: Turn the crankshaft using socket wrench. see scheme 19: Identifying Mark On Cam Sprocket
13. Measure the #1 cylinder intake valve and #3 cylinder exhaust valve clearance by using thickness gauge (A). NOTE: Insert a thickness gauge in a direction as horizontal as possible with respect to the valve lifter. Measure the exhaust valve clearances while lifting-up the vehicle. Valve clearance: Intake 0.20 ± 0.02 mm (0.0079 ± 0.0008 in) Exhaust 0.35 ± 0.02 mm (0.0138 ± 0.0008 in) If the measured value is not within specification, take notes of the value in order to adjust the valve clearance later on. see scheme 20: Measuring Exhaust Valve Clearances Using Thickness Gauge
14. If necessary, adjust the valve clearance. ADJUSTMENT VALVE CLEARANCE.>
15. Further turn the crank pulley clockwise. Using the same procedures described previously, then measure valve clearances again. Set the arrow mark on cam sprocket to the position shown in the figure, and measure the #2 cylinder exhaust valve and #3 cylinder intake valve clearances. see scheme 21: Position Of Arrow Mark On Cam Sprocket (1 Of 3) Set the arrow mark on cam sprocket to the position shown in the figure, and measure the #2 cylinder intake valve and #4 cylinder exhaust valve clearances. see scheme 22: Position Of Arrow Mark On Cam Sprocket (2 Of 3) Set the arrow mark on cam sprocket to the position shown in the figure, and measure the #1 cylinder exhaust valve and #4 cylinder intake valve clearances. see scheme 23: Position Of Arrow Mark On Cam Sprocket (3 Of 3)
16. After inspection, install the related parts in the reverse order of removal. Tightening torque: 33 N.m (3.4 kgf-m, 25 ft-lb) see scheme 24: Locating Bolts

Make sure that no crack or other damage do not exists.

Scheme 323

1. After removing the engine from body, secure it to ST in the following procedure. ST1 498457000 ENGINE STAND ADAPTER RH ST2 498457100 ENGINE STAND ADAPTER LH ST3 499817100 ENGINE STAND see scheme 60: Identifying ST1 498457000 Engine Stand Adapter RH, ST2 498457100 LH And ST3 499817100 Engine Stand
2. In this article the procedures described under each index are all connected and stated in order. The procedure for overhauling of the engine will be completed when you go through all steps in the process. Therefore, in this article, to conduct the particular procedure within the flow of a information, you need to go back and conduct the procedure described previously in order to do that particular procedure.

1. Check the V-belt is not worn or otherwise damaged.
2. Check the tension of the belt. INSPECTION V-BELT.>

Make sure the cover is not damaged.

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1. Remove the V-belts. REMOVAL V-BELT.>
2. Remove the crank pulley. REMOVAL CRANK PULLEY.>
3. Remove the timing belt cover. REMOVAL TIMING BELT COVER.>
4. Remove the timing belt guide. (MT model) see scheme 73: Locating Timing Belt Guide (MT Model) see scheme 74: Locating Timing Belt Guide Bolt (1 Of 3) see scheme 75: Locating Timing Belt Guide Bolt (2 Of 3) see scheme 76: Locating Timing Belt Guide Bolt (3 Of 3)
5. If the alignment mark or arrow mark (which indicates rotation direction) on timing belt fade away, put new marks before removing the timing belt as shown in procedures below. Turn the crankshaft using ST, and align the alignment marks on crank sprocket, intake cam sprocket (LH), exhaust cam sprocket (LH), intake cam sprocket (RH) and exhaust cam sprocket (RH) with notches of timing belt cover and cylinder block. ST 499987500 CRANKSHAFT SOCKET see scheme 77: Turning Crankshaft Using Crankshaft Socket ST 499987500 Using white paint, put alignment and/or arrow marks on timing belts in relation to the cam sprockets. see scheme 78: Aligning Alignment Marks On Timing Belts In Relation To Cam Sprockets (1 Of 2) see scheme 79: Aligning Alignment Marks On Timing Belts In Relation To Cam Sprockets (2 Of 2) Z 1: 54.5-tooth length Z 2: 51-tooth length Z 3: 28-tooth length
6. Remove the belt idler (A). see scheme 81: Identifying Belt Idler
7. Remove the timing belt. CAUTION: After the timing belt has been removed, never rotate the intake and exhaust sprocket. If the cam sprocket is rotated, the intake and exhaust valve heads strike together and valve stems are bent.

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1. Remove the belt idler (B) and (C). see scheme 82: Identifying Belt Idler
2. Remove the belt idler No. 2. see scheme 83: Identifying Belt Idler No.2
3. Remove the automatic belt tension adjuster assembly. see scheme 84: Identifying Automatic Belt Tension Adjuster Assembly

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1. Preparation for installation of automatic belt tension adjuster assembly. CAUTION: 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 three minutes. Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lbf). Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into 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 vertical pressing tool. Slowly move the adjuster rod down with a pressure of more than 294 N (30 kgf, 66 lb) until the adjuster rod is aligned with the stopper pin hole in the cylinder. see scheme 85: Pressing Adjuster Rod 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. see scheme 86: Identifying Stopper Pin Inserted Into Stopper Pin Hole
2. Install the automatic belt tension adjuster assembly. Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb) see scheme 87: Identifying Automatic Belt Tension Adjuster Assembly
3. Install the belt idler No. 2. Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb) see scheme 88: Identifying Belt Idler No.2
4. Install the belt idlers. Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb) see scheme 89: Identifying Belt Idlers

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1. Preparation for installation of automatic belt tension adjuster assembly. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER INSTALLATION, TIMING BELT.>
2. Crankshaft and camshaft sprocket alignment Align the mark (A) on crank sprocket with the mark on oil pump cover at cylinder block. see scheme 90: Aligning Mark On Crank Sprocket With Mark On Oil Pump Cover Cylinder Block Align single line mark (A) on the exhaust cam sprocket (RH) with notch (B) on timing belt cover. see scheme 91: Aligning Single Line Mark On Exhaust Cam Sprocket Align single line mark (A) on the intake cam sprocket (RH) with notch (B) on timing belt cover. (Ensure double lines (C) on intake and exhaust camshaft sprockets are aligned.) see scheme 92: Aligning Single Line Mark On Intake Cam Sprocket Align the single line mark (A) on exhaust cam sprocket (LH) with notch (B) on timing belt cover by turning the sprocket counterclockwise (as viewed from front of engine). (Scheme 324): Aligning Single Line Mark On Exhaust Cam Sprocket Align the single line mark (A) on intake cam sprocket (LH) with notch (B) on timing belt cover by turning the sprocket clockwise (as viewed from front of engine). (Make sure the double line marks (C) on intake and exhaust cam sprockets are aligned.) (Scheme 325): Aligning Single Line Mark On Intake Cam Sprocket Make sure that the cam and crank 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, the valve heads will interfere with each other, resulting in bent valves. (Scheme 326): Identifying Intake And Exhaust Camshaft 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.) Right-side camshafts 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 with the smallest possible angle, 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 of upper one. Doing this cause both the intake and exhaust valves to lift simultaneously, resulting in interference with their heads. (Scheme 327): Identifying Timing Belt Installation Position With Rotating Direction
3. Installation of timing belt: Align the alignment mark on the timing belt with marks on the sprockets in the 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. Make sure the belt's rotating direction is correct. (Scheme 328): Identifying Arrow Mark, Timing Belt And Tooth Length
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. (Scheme 329): Identifying Belt Idler
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) (Scheme 330): Identifying Clearance Between Timing Belt And Timing Belt Guide (1 Of 4) (Scheme 331): Identifying Clearance Between Timing Belt And Timing Belt Guide (2 Of 4) (Scheme 332): Identifying Clearance Between Timing Belt And Timing Belt Guide (3 Of 4) (Scheme 333): Identifying Clearance Between Timing Belt And Timing Belt Guide (4 Of 4) Tighten the bolt. Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb) (Scheme 334): Locating Timing Belt Guide Bolts (1 Of 4) Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) (Scheme 335): Locating Timing Belt Guide Bolt (2 Of 4) Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) (Scheme 336): Locating Timing Belt Guide Bolt (3 Of 4) Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) (Scheme 337): Locating Timing Belt Guide Bolt (4 Of 4)
7. Install the timing belt cover. INSTALLATION TIMING BELT COVER.>
8. Install the crank pulley. INSTALLATION CRANK PULLEY.>
9. Install the V-belts. INSTALLATION V-BELT.>

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

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

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1. Remove the V-belts. REMOVAL V-BELT.>
2. Remove the crank pulley. REMOVAL, CRANK PULLEY.>
3. Remove the timing belt cover. REMOVAL, TIMING BELT COVER.>
4. Remove the timing belt. REMOVAL, TIMING BELT.>
5. Remove the cam sprocket. REMOVAL, CAM SPROCKET.>
6. Disconnect the oil flow control solenoid valve assembly connector. (Scheme 345): Locating Oil Flow Control Solenoid Valve Assembly Connector
7. Remove the tensioner bracket. (Scheme 346): Locating Tensioner Bracket
8. Remove the timing belt cover No. 2 (LH). (Scheme 347): Identifying Timing Belt Cover Bolt No.2 (LH)
9. Remove the timing belt cover No. 2 (RH). (Scheme 348): Identifying Timing Belt Cover No.2 (RH)
10. Remove the spark plug cords.
11. Remove the oil level gauge guide. (LH side)
12. Remove the rocker cover and gasket.
13. Remove the oil pipe. (Scheme 349): Locating Oil Pipe
14. Loosen the oil flow control solenoid valve assembly and intake camshaft cap bolts equally, a little at a time in alphabetical sequence shown in the figure. (Scheme 350): Identifying Intake Camshaft Cap Bolts Loosening Sequence
15. Loosen the exhaust camshaft cap bolts equally, a little at a time in alphabetical sequence shown in the figure. (Scheme 351): Identifying Exhaust Camshaft Cap Bolts Loosening Sequence
16. Remove the oil flow control solenoid valve assembly, intake camshaft cap and camshaft.
17. Remove the exhaust camshaft caps and camshaft. NOTE: Arrange camshaft caps in order so that they can be installed in their original positions.
18. Similarly, remove the camshafts (RH) and related parts.

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1. Camshaft installation: Apply engine oil to the cylinder head at camshaft bearing installation location before installing the camshaft. Install the camshaft so that each valve is close to or in contact with base circle of the cam. NOTE: Set the cam shaft to the position shown in the figure. It is necessary to rotate the cam shaft (LH) slightly when installing the timing belt. Camshaft RH must be rotated when set at the position shown in the figure. Intake camshaft LH: Rotate 80° clockwise. Exhaust camshaft LH: Rotate 45° clockwise. (Scheme 352): Positioning Cam Shaft
2. Camshaft cap and oil flow control solenoid valve assembly installation: Apply small amount of liquid gasket to the mating surface of cap. NOTE: Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to come out and flow toward oil seal, resulting in oil leak. Liquid gasket: Three Bond 1215 (Part No. 004403007) or equivalent see scheme 123: Identifying Liquid Gasket Applying Surface Apply a thin coat of engine oil to cap bearing surface, and install the cap to the camshaft. 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, 7.2 ft-lb) T2: 20 N.m (2.0 kgf-m, 14.5 ft-lb) see scheme 124: Identifying Camshaft Cap Bolts Tightening Sequence After tightening the camshaft cap, ensure the camshaft rotates only slightly while holding it at base circle.
3. Camshaft oil seal installation: Apply grease to the new oil seal lips and press onto the front end of camshaft by using ST1 and ST2. NOTE: Replace the oil seal with a new one. ST1 499587600 OIL SEAL INSTALLER ST2 499597200 OIL SEAL GUIDE see scheme 125: Installing Camshaft Oil Seal Using Oil Seal Guide ST1 499587600 And Oil Seal Guide ST2 499597200
4. Rocker cover installation: Install the gasket on rocker cover. Install the peripheral gasket and ignition coil unit gasket. Apply liquid gasket to the specified point of the cylinder head. Apply extra amount of liquid gasket around plugs 5 mm (0.2 in) or more. Liquid gasket: Three Bond 1215 (Part No. 004403007) or equivalent see scheme 126: Identifying Liquid Gasket Applying Area Install the rocker cover on cylinder head. Ensure the gasket is properly positioned during installation. Temporarily 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) see scheme 127: Identifying Rocker Cover Bolts Tightening Sequence
5. Install the oil pipe. NOTE: Make sure not to mix up the union screws with filter and without filter as their installation positions are different. Tightening torque: 29 N.m (3.0 kgf-m, 21.4 ft-lb) see scheme 128: Identifying Union Screws
6. Connect the oil flow control solenoid valve connector. see scheme 129: Identifying Oil Flow Control Solenoid Valve Assembly Connector
7. Similarly, install the parts on right-hand side.
8. Install the timing belt cover No. 2 (RH). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb) see scheme 130: Identifying Timing Belt Cover No. 2 (RH)
9. Install the timing belt cover No. 2 (LH). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb) see scheme 131: Identifying Timing Belt Cover Bolt No.2 (LH)
10. Install the tensioner bracket. Tightening torque: 24.5 N.m (2.5 kgf-m, 18.1 ft-lb) see scheme 132: Identifying Tensioner Bracket
11. Install the cam sprocket. INSTALLATION, CAM SPROCKET.>
12. Install the timing belt. INSTALLATION TIMING BELT.>
13. Install the timing belt cover. INSTALLATION TIMING BELT COVER.>
14. Install the crank pulley. INSTALLATION CRANK PULLEY.>
15. Install the V-belts. INSTALLATION V-BELT.>

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1. Measure the bend, and repair or replace if necessary. Service limit: 0.020 mm (0.0008 in) see scheme 133: Measuring Camshaft Runout
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 at specified, check the oil clearance. DIAMETER OF CAMSHAFT JOURNAL Camshaft journal Front Center, rear Standard 37.946 - 37.963 mm (1.4939 -1.4946 in) 29.946 - 29.963 mm (1.1790 -1.1796 in)
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 lifter) Place a plastigauge across each 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) (Scheme 353): Identifying Camshaft Bearing Caps Bolts Tightening Sequence Remove the bearing caps. Measure the widest point of the 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) Service limit: 0.10 mm (0.0039 in) (Scheme 354): Measuring Widest Point Of Plastigauge 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 it exceeds the limit. 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) Service 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) (Scheme 355): Identifying Cam Height And Cam Base Circle Diameter
6. Measure the thrust clearance of camshaft with setting the dial gauge at end of camshaft. If the thrust 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) Service limit: 0.14 mm (0.0055 in) (Scheme 356): Measuring Thrust Clearance Of Camshaft

Scheme 372

1. Remove the V-belts. REMOVAL, V-BELT.>
2. Remove the crank pulley. REMOVAL, CRANK PULLEY.>
3. Remove the timing belt cover. REMOVAL, TIMING BELT COVER. >
4. Remove the timing belt. REMOVAL, TIMING BELT. >
5. Remove the cam sprocket. REMOVAL, CAM SPROCKET. >
6. Remove the intake manifold. REMOVAL, Intake Manifold. >
7. Remove the bolt which installs the A/C compressor bracket on cylinder head.
8. Remove the camshaft. REMOVAL, CAMSHAFT. >
9. Remove the cylinder head bolts in alphabetical sequence shown in the figure. Leave the bolts (A) and (D) engaged by three or four threads to prevent the cylinder head from falling. (Scheme 357): Identifying Cylinder Head Bolts Removal Sequence
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. (Scheme 358): Identifying Cylinder Head Bolts
11. Remove the cylinder head gasket. CAUTION: Be careful not to scratch the mating surface of cylinder block and cylinder head.
12. Similarly, remove the cylinder head (RH).

Scheme 373

1. Install the cylinder head and gaskets on cylinder block. CAUTION: Replace with a new cylinder head gasket. Be careful not to scratch the mating surface of cylinder block and cylinder head.
2. Tighten the cylinder head bolts. Apply a thin coat of engine oil to washer and bolt thread. 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. Loosen all the bolts by 180° in the reverse order of tightening, and loosen them again by 180°. Tighten all bolts to 49 N.m (5.0 kgf-m, 36 ft-lb) in alphabetical sequence. Tighten all bolts by 80 to 90° in alphabetical sequence. Tighten all bolts by 40 to 45° in alphabetical sequence. CAUTION: Do not tighten the bolts more than 45°. Further tighten the bolts (A) and (B) by 40 to 45°. CAUTION: Make sure the total "re-tightening angle" of the previous step (2) does not exceed 90°. (Scheme 359): Identifying Cylinder Head Bolts Tightening Sequence
3. Install the camshaft. INSTALLATION, CAMSHAFT. >
4. Install the A/C compressor bracket on cylinder head.
5. Install the intake manifold. INSTALLATION, Intake Manifold. >
6. Install the cam sprocket. INSTALLATION, CAM SPROCKET. >
7. Install the timing belt. INSTALLATION, TIMING BELT. >
8. Install the timing belt cover. INSTALLATION, TIMING BELT COVER. >
9. Install the crank pulley. INSTALLATION, RANK PULLEY. >
10. Install the V-belts. INSTALLATION, V-BELT. >

Scheme 374

1. Remove the valve lifter.
2. Compress the valve spring and remove the valve spring retainer key. Remove each valve and valve spring. ST1 498267600 CYLINDER HEAD TABLE ST2 499718000 VALVE SPRING REMOVER NOTE: Keep all the removed parts in order for re-installing in their original positions. CAUTION: Mark each valve to prevent confusion. Pay careful attention not to damage the lips of intake valve oil seals and exhaust valve oil seals. (Scheme 360): Identifying ST1 498267600 Cylinder Head Table, ST2 499718000 Valve Spring Remover

Scheme 375

1. Installation of valve spring and valve: Coat the stem of each valve with engine oil and insert the valve into valve guide. NOTE: When inserting the valve into valve guide, use special care not to damage the oil seal lip. Set the cylinder head on ST1. Install the valve spring and retainer using ST2. ST1 498267600 CYLINDER HEAD TABLE ST2 499718000 VALVE SPRING REMOVER NOTE: Be sure to install the valve spring with its close-coiled end facing the seat on cylinder head. (Scheme 362): Identifying ST1 498267600 Cylinder Head Table, ST2 499718000 Valve Spring Remover Compress the valve spring and install the retainer key. After installing, tap the valve spring retainers lightly with a wooden hammer for better seating.
2. Apply oil to the surfaces of the valve lifter.
3. Install the valve lifter.

Scheme 376

1. Visually check for cracks and damage. Use liquid penetrant tester on the important sections to check for fissures.
2. Measure the warping of the cylinder head surface that mates with crankcase using a straight edge (A) and thickness gauge (B). If the warping exceeds 0.035 mm (0.0014 in), re-grind the surface with a surface grinder. Service limit: 0.035 mm (0.0014 in) Grinding limit: 0.3 mm (0.012 in) Standard height of cylinder head: 127.5 mm (5.02 in) NOTE: The cylinder can become warped if the head bolts are tightened at ununiform torques when installing the cylinder head. (Scheme 363): Measuring Warping Of Cylinder Head Surface

Note. "RANK" shown in the chart refers to the possibility of the cause of trouble in order "Very often" to "Rarely"

A - Very often

B - Sometimes

C - Rarely

ENGINE TROUBLE SYMPTOM CHART

ENGINE NOISE TROUBLE SYMPTOM CHART