Engine Mechanical (H4DOTC): Other Subaru Forester SH

CAUTION

1. Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work.
2. Remove contamination including dirt and corrosion before removal, installation or disassembly.
3. Keep the disassembled parts in order and protect them from dust and dirt.
4. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
5. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.
6. Be sure to tighten fasteners including bolts and nuts to the specified torque.
7. Place shop jacks or rigid racks at the specified points.
8. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery.
9. All parts should be thoroughly cleaned, paying special attention to 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 engine 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 parts as required.
14. Even if necessary inspections have been made in advance, proceed with assembly work while making re-checks.
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 not to stain seats and windows with coolant or oil. Place a cover over fender, 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.

1. Lift up or lower the vehicle when necessary. Make sure to support the correct positions.

GENERAL TOOL

GENERAL TOOL REFERENCE

PROCEDURE

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

1. V-belt
2. Timing belt
3. Camshaft
4. Cylinder head

METHOD WITH SUBARU SELECT MONITOR

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. Read the ignition timing using Subaru Select Monitor. Refer to «READ CURRENT DATA FOR ENGINE (NORMAL MODE)»(ref-325335-S37463705132009071800000) , OPERATION, Subaru Select Monitor .

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

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

METHOD WITH TIMING LIGHT

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. Remove the collector cover.
5. Remove the air intake duct (rear).
6. Disconnect the connectors of the mass air flow and intake air temperature sensor.
7. Remove the air cleaner case and element.
8. Connect the timing light to the power wire of #1 ignition coil.
9. Attach the air cleaner case, element and connector of mass air flow and intake air temperature sensor.
10. Start the engine, turn the timing light to the crank pulley, and check the ignition timing by means of crank pulley indicator.

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

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

REAR SIDE BELT

1. Remove the front side belts. Refer to «FRONT SIDE BELT»(ref-325302-S29866740192009071800000) , REMOVAL, V-belt .
2. Cut the rear side belt with a wire cutter, etc., and discard.

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FRONT SIDE BELT

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1. Wipe off any sand, dust, oil or water from the pulley grooves with a cloth.
2. Install the front side belt (C), and adjust the slider bolt (B) so as to obtain the specified belt tension. Refer to «INSPECTION»(ref-325302-S10218105432009071800000) , V-belt .
3. Tighten the bolt (A).
4. Tighten the slider bolt (B). Tightening torque: Bolt (A) 25 N.m (2.5 kgf-m, 18.4 ft-lb) Slider bolt (B) 8 N.m (0.8 kgf-m, 5.9 ft-lb)
5. Install the collector cover bracket. Tightening torque: T1: 8.5 N.m (0.9 kgf-m, 6.3 ft-lb) T2: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
6. Install the air intake duct (rear). Refer to «INSTALLATION»(ref-325300-S02354694642009071800000) , Air Intake Duct .
7. Install the collector cover.

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1. Wipe off any sand, dust, oil or water from the pulley grooves with a cloth.
2. Wipe off any oil, water, mud or rust attached to the front side of the crank pulley with a cloth.
3. Turn the crank pulley to the right slowly, until the crank pulley service hole near the top. CAUTION: Never turn the crank pulley to the left.
4. Attach a new rear side belt on the A/C compressor belt.
5. Insert the claw of the belt stopper (A) into the lower hole (B) on the compressor bracket as shown in the figure, and attach using bolt (C).
6. Mount the belt guide by matching to the belt line on the front side belt of the crank pulley.
7. Insert the belt guide holder into the crank pulley service hole so as to clamp the belt guide. NOTE: The longer side of the belt guide holder is the upper side.
8. Turn the crank pulley slowly to the right, and set the belt guide at an approximately 45° position.
9. Place the rib face of the rear side belt onto the grooves of the crank pulley, and sandwich the rear side belt with the belt guide holder. CAUTION: If the rear side belt does not fit onto the groove of the crank pulley easily, pull out the belt guide holder halfway, then insert the rear side belt into the groove, and sandwich it with the belt guide holder.
10. Place the tool through the loop of the rear side belt, and set on the crank pulley belt.
11. While checking for the following, turn the crank pulley slowly to the right by approximately 90° and set the belt guide to the position shown in the figure. CAUTION: When rotating the crank pulley, be careful that the belt guide does not deviate from the groove of the crank pulley. The ribs of the rear side belt are properly riding on the grooves of the A/C compressor pulley. The ribs of the rear side belt are properly riding on the grooves of the crank pulley. The surface of the rear side belt is being pressed by the belt stopper. The rear side belt is riding properly on the belt guide.
12. While checking for the following, turn the crank pulley slowly to the right by approximately 90° and set the belt guide to the position shown in the figure. The rear side belt is not twisted. The ribs of the rear side belt are properly riding on the grooves of the A/C compressor pulley. The ribs of the rear side belt are properly riding on the grooves of the crank pulley. The surface of the rear side belt is being pressed by the belt stopper. The rear side belt is riding properly on the belt guide.
13. Turn the crank pulley slowly to the right, and attach the rear side belt. CAUTION: Because there is a possibility of damage to the rear side belt, and the belt guide holder falling off, care must be taken to make sure that the total of steps 8), 11), 12), and 13) does not exceed 330°.
14. Remove the belt guide and belt guide holder from the crank pulley.
15. Remove the belt stopper from the compressor bracket. CAUTION: Make sure to remove the belt stopper, as leaving it on can cause smoke, flames or belt breakage.
16. Make sure that the belt ribs are properly riding on the grooves of the pulleys, and turn the crank pulley slowly to the right twice to break in the rear side belt.
17. Discard the provided tools (belt stopper, belt guide, belt guide holder, bolt).
18. Install the front side belt. Refer to «FRONT SIDE BELT»(ref-325302-S29866740192009071800000) , INSTALLATION, V-belt .

1. Replace the front side belt, if cracking, fraying or wear is found.
2. Check the front side belt tension and adjust it if necessary by adjusting the generator installing position.

Front side belt tension (when using a belt tension gauge)

When installing new parts

640 - 780 N (65 - 80 kgf, 144 - 175 lbf)

At inspection

490 - 640 N (50 - 65 kgf, 110 - 144 lbf)

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Front side belt tension (when not using a belt tension gauge)

When installing new parts

7 - 9 mm (0.276 - 0.354 in)

At inspection

9 - 11 mm (0.354 - 0.433 in)

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If cracks, fraying or wear is found, and when abnormal noise is produced, replace the rear side belt.

Note. Because the rear side belt is a stretch type belt, it is not necessary to check deflection and tension.

TIMING BELT

1. Check the timing belt teeth for breaks, cracks or wear. If any fault is found, replace the timing belt.
2. Check the condition on the back surface of the timing belt. If cracks are found, replace the timing belt.

In radial diameter 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 and scratches. If necessary, replace the automatic belt tension adjuster assembly. NOTE: Slight traces of oil on the oil seal of the rod does not indicate a problem.
2. Check that the adjuster rod does not move when a pressure of 165 N (16.8 kgf, 37.1 lbf) is applied to it. In this check, it is possible to check the stiffness of the adjuster rod.
3. If the adjuster rod is not stiff and moves freely when applying 165 N (16.8 kgf, 37.1 lbf), check it using the following procedures: Slowly press the adjuster rod down to the end surface of cylinder. Repeat this operation two to three times. With the adjuster rod moved all the way up, apply a pressure of 165 N (16.8 kgf, 37.1 lbf) 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 part. 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 three minutes or more. Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lbf). Push in the adjuster rod to the end face of the cylinder. However, do not press the adjuster rod below the end face of the cylinder. Doing so may damage the cylinder.
4. Measure the amount of rod protrusion "H" from the end surface of body. If it is not within the specified range, replace with a new part.

Amount of rod protrusion H: 5.2 - 6.2 mm (0.205 - 0.244 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 automatic belt tension adjuster assembly with a new part if faulty.
2. Check the belt tension pulley for smooth rotation. Replace the automatic belt tension adjuster assembly with a new part if abnormal noise or excessive play occurs.
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 occurs.
2. Check the outer contacting surfaces of idler pulley for abnormal wear and scratches.
3. Check the belt idler for grease leakage.

CYLINDER HEAD

1. Check for cracks or damage. Use liquid penetrant tester on the important sections to check for fissures. Check that there are no marks of gas leaking or water leaking on gasket installing surface.
2. Measure the warping of the cylinder head surface that mates with cylinder block using a straight edge (A) and thickness gauge (B).

If the warping exceeds the limit, correct the surface by grinding it with a surface grinder.

Warping 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. Uneven torque for the cylinder head bolts can cause warping. When reinstalling, 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 correct the contact surfaces with a valve seat cutter if they are defective or when valve guides are replaced.

Valve seat width W

Standard

Intake

0.6 - 1.4 mm (0.024 - 0.055 in)

Exhaust

1.2 - 1.8 mm (0.047 - 0.071 in)

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VALVE GUIDE

1. Check the clearance between valve guide and valve stem. The clearance can be checked by measuring respectively the outer diameter of valve stem with a micrometer and the inner diameter of valve guide with a caliper gauge. 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)
2. If the clearance between valve guide and valve stem exceeds the standard, replace the valve guide or valve itself whichever shows greater amount of wear or damaged and etc. 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)

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1. Place the cylinder head on ST1 with the combustion chamber upward so that valve guides fit the holes in ST1.
2. 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 the 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 inner surface of valve guide holes in cylinder head.
5. Put a new valve guide, coated with sufficient oil, in the cylinder head, and insert the 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 using ST. Put the ST in valve guide, and rotate the ST slowly clockwise while pushing it lightly. Bring the ST back while rotating it clockwise. NOTE: Apply engine oil to the ST when reaming. If the inner surface of valve guide is damaged, the edge of ST should be slightly ground with oil stone. If the inner surface of valve guide becomes lustrous and the ST does not chip, use a new ST or remedy the ST. ST 499767400 VALVE GUIDE REAMER
8. After reaming, clean the valve guide to remove chips.
9. 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 the valve with a new part if damaged, worn, deformed, or if dimension "H" in the figure is outside of the specified limit. Head edge thickness H: Standard Intake (A) 1.0 - 1.4 mm (0.039 - 0.055 in) Exhaust (B) 1.3 - 1.7 mm (0.051 - 0.067 in)
2. Put a small amount of grinding compound on the seat surface, and lap the valve and seat surface. Replace with a new valve oil seal after lapping.

Note. It is possible to differentiate between the intake valve and the exhaust valve by their overall length.

Valve overall length

Intake

104.4 mm (4.110 in)

Exhaust

104.65 mm (4.1201 in)

VALVE SPRING

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

SPRING HEIGHT SPECIFICATION

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INTAKE AND EXHAUST VALVE OIL SEAL

1. For the following, replace the oil seal with a new part. See procedure 2 ) and subsequent for replacement procedures. When the lip is damaged. When the spring is out of the specified position. When readjusting the surfaces of valve and valve seat. When replacing the valve guide.
2. Place the cylinder head on ST1, and use ST2 to press-fit the oil seal. ST1 498267600 CYLINDER HEAD TABLE ST2 498857100 VALVE OIL SEAL GUIDE

Note. Apply engine oil to oil seal before press-fitting. When press-fitting the oil seal, do not use a hammer, etc. or strike in. The intake valve oil seals and exhaust valve oil seals are distinguished by their colors.

Color of rubber part

Intake [Gray]

Exhaust [Green]

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1. Check the valve lifter visually.
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 surface on cylinder head.

Inner diameter

34.994 - 35.076 mm (1.3777 - 1.3786 in)

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Note. If difference between outer diameter of valve lifter and inner diameter of its mating surface is not within the standard or there is uneven wear, replace the cylinder head.

Standard

0.019 - 0.057 mm (0.0007 - 0.0022 in)

CYLINDER BLOCK

1. Check for cracks or damage. Use liquid penetrant tester on the important sections to check for fissures. Check that there are no marks of gas leaking or water leaking on gasket installing surface.
2. Check the oil passages for clogging.
3. Inspect the cylinder block surface that mates with cylinder head for warping by using a straight edge, and correct by grinding if necessary.

Warping limit

0.025 mm (0.00098 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 the front upper face of the cylinder block. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Standard sized pistons are classified into two grades, "A" and "B". These grades should be used as guide lines 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. Measure the inner diameters of the cylinders. Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights as 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) Out-of-roundness: Standard 0.010 mm (0.0004 in)
3. When the piston is to be replaced due to general or cylinder wear, select a suitable sized piston by measuring the piston clearance.
4. Measure the outer diameters of the cylinders. Measure the outer diameter of each piston at the height as 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 (-0.00039 - 0.00039 in)
6. Boring and honing

1. If any measured value of taper, out-of-roundness or cylinder-to-piston clearance is out of standard or if there is any damage on the cylinder wall, rebore the cylinder for replacement to an oversized piston. CAUTION: When any of the cylinders needs reboring, all other cylinders must also be bored at the same time, and replaced with oversize pistons.
2. If the cylinder inner diameter exceeds the limit after boring and honing, replace the cylinder block.

Note. Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, when measuring the cylinder diameter, wait until it has cooled to room temperature.

Cylinder inner diameter boring limit (diameter): To 100.005 mm (3.9372 in)

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1. Check the piston and piston pin for breaks, cracks or wear. Replace if faulty.
2. Check the piston ring groove for wear and damage. Replace if faulty.
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 faulty. Standard clearance between piston pin and hole in piston: Standard 0.004 - 0.008 mm (0.0002 - 0.0003 in)
4. Check the snap ring installation groove (A) on the piston for burr. If necessary, remove burr from the groove so that the piston pin can lightly move.
5. Check the piston pin snap ring for distortion, cracks and wear.

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1. If the piston ring is broken, damaged, worn, its tension is insufficient, or when replacing the piston, replace with a new piston ring of the same size as the piston. NOTE: The top ring and second ring have the mark to determine the direction to install on them. When installing the ring to piston, face this mark to the top side. Oil ring consists of the upper rail, expander and lower rail. When installing oil ring on piston, be careful of the direction of each rail.
2. Squarely place the piston ring and oil ring in cylinder using the piston, and measure the piston ring gap with a thickness gauge. PISTON RING GAP STANDARD SPECIFICATION Standard mm (in) Piston ring gap Top ring 0.20 - 0.25 (0.0079 - 0.0098) Second ring 0.37 - 0.52 (0.015 - 0.020) Oil ring rail 0.20 - 0.50 (0.0079 - 0.0197)
3. Fit the piston ring straight into the piston ring groove, then 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.

STANDARD SPECIFICATION

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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 the crankshaft, and measure the thrust clearance using a thickness gauge. If the thrust clearance exceeds the standard or uneven wear is found, replace the connecting rod. Connecting rod thrust clearance: Standard 0.070 - 0.330 mm (0.0028 - 0.0130 in)
4. Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc.
5. Measure the oil clearance on each connecting rod bearing using plastigauge. If any oil clearance is not within the standard, replace the defective bearing with a new part of standard size or undersize as necessary. Connecting rod oil clearance: Standard 0.017 - 0.045 mm (0.0007 - 0.0018 in) CONNECTING ROD OIL CLEARANCE SPECIFICATION Unit: mm (in) Bearing Bearing size (Thickness at center) Outer diameter of crank pin Standard 1.490 - 1.502 (0.0587 - 0.0591) 51.984 - 52.000 (2.0466 - 2.0472) 0.03 (0.0012) undersize 1.504 - 1.512 (0.0592 - 0.0595) 51.954 - 51.970 (2.0454 - 2.0461) 0.05 (0.0020) undersize 1.514 - 1.522 (0.0596 - 0.0599) 51.934 - 51.950 (2.0447 - 2.0453) 0.25 (0.0098) undersize 1.614 - 1.622 (0.0635 - 0.0639) 51.734 - 51.750 (2.0368 - 2.0374)
6. Inspect the bushing at connecting rod small end, and replace with a new part if worn or damaged.
7. Measure the piston pin clearance at connecting rod small end. If the measured value is not within the standard, replace it with a new part. Clearance between piston pin and bushing: Standard 0 - 0.022 mm (0 - 0.0009 in)
8. The replacement procedure for the connecting rod small end bushing is as follows.

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1. Remove the bushing from connecting rod with ST and press.
2. Press the bushing with the ST after applying oil on the periphery of new bushing. ST 499037100 CONNECTING ROD BUSHING REMOVER AND INSTALLER
3. Make two 3 mm (0.12 in) holes in the pressed bushing by aligning with the pre-manufactured holes on the connecting rod, and ream the inside of the bushing.
4. After completion of reaming, clean the bushing to remove chips.

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1. Clean the crankshaft completely, and check it for cracks using liquid penetrant tester. If defective, replace the crankshaft.
2. Measure warping of the crankshaft. If it exceeds the limit, correct or replace it. NOTE: If a suitable V-block is not available, using just the #1 and #5 crankshaft bearings on cylinder block, position the crankshaft on cylinder block. Then, 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 specification, replace the bearing with a suitable (undersize) one, and replace or grind to correct the crankshaft as necessary. When grinding the crank journal or crank pin, finish them to the specified dimensions according to the undersize bearing to be used. Crank pin: Out-of-roundness 0.003 mm (0.0001 in) Cylindricality 0.004 mm (0.0002 in) Grinding limit (dia.) To 51.750 mm (2.0374 in) Crank journal: Out-of-roundness 0.005 mm (0.0002 in) Cylindricality 0.006 mm (0.0002 in) Grinding limit (dia.) To 59.758 mm (2.3527 in) CRANK SPECIFICATION Unit: mm (in) Crank journal diameter Crank pin outer diameter #1,#3 #2, #4, #5 Standard Journal O.D. 59.992 - 60.008 (2.3619 - 2.3625) 59.992 - 60.008 (2.3619 - 2.3625) 51.984 - 52.000 (2.0466 - 2.0472) Bearing size (Thickness at center) 1.998 - 2.011 (0.0787 - 0.0792) 2.000 - 2.013 (0.0787 - 0.0793) 1.490 - 1.502 (0.0587 - 0.0591) 0.03 (0.0012) undersize Journal O.D. 59.962 - 59.978 (2.3607 - 2.3613) 59.962 - 59.978 (2.3607 - 2.3613) 51.954 - 51.970 (2.0454 - 2.0461) Bearing size (Thickness at center) 2.017 - 2.020 (0.0794 - 0.0795) 2.019 - 2.022 (0.0795 - 0.0796) 1.504 - 1.512 (0.0592 - 0.0595) 0.05 (0.0020) undersize Journal O.D. 59.942 - 59.958 (2.3599 - 2.3605) 59.942 - 59.958 (2.3599 - 2.3605) 51.934 - 51.950 (2.0447 - 2.0453) Bearing size (Thickness at center) 2.027 - 2.030 (0.0798 - 0.0799) 2.029 - 2.032 (0.0799 - 0.0800) 1.514 - 1.522 (0.0596 - 0.0599) 0.25 (0.0098) undersize Journal O.D. 59.742 - 59.758 (2.3520 - 2.3527) 59.742 - 59.758 (2.3520 - 2.3527) 51.734 - 51.750 (2.0368 - 2.0374) Bearing size (Thickness at center) 2.127 - 2.130 (0.0837 - 0.0839) 2.129 - 2.132 (0.0838 - 0.0839) 1.614 - 1.622 (0.0635 - 0.0639)
4. Use a thickness gauge to measure the thrust clearance of the crankshaft at the #5 crank journal bearing. If clearance exceeds the standard, replace the bearing. Crankshaft thrust clearance: Standard 0.030 - 0.115 mm (0.0012 - 0.0045 in)
5. Inspect individual crankshaft bearings for signs of flaking, seizure, melting and wear.
6. Measure the oil clearance on each crankshaft bearing using plastigauge. If the measured value is out of standard, replace the defective bearing with an undersize one, and replace or grind to correct the crankshaft as necessary.

Crankshaft oil clearance

Standard

0.010 - 0.030 mm (0.0004 - 0.0012 in)