Engine Mechanical (H4DOTC): Removal & Installation Subaru Forester SH

REMOVAL

1. Remove the engine unit. Refer to «REMOVAL»(ref-325302-S02713656432009071800000) , Engine Assembly .
2. Remove the engine mounting from engine assembly.

INSTALLATION

Install in the reverse order of removal.

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

Note. Perform the work with the engine installed to body when replacing a single part.

Scheme 337

1. Remove the collector cover.
2. Remove the air intake duct (rear). Refer to «REMOVAL»(ref-325300-S04200539772009071800000) , Air Intake Duct .
3. Remove the collector cover bracket.
4. Loosen the bolt (A).
5. Loosen the slider bolt (B).
6. Remove the front side belt (C).

Scheme 338

Note. Perform the work with the engine installed to body when replacing a single part.

Scheme 339

1. Remove the V-belts. Refer to «REMOVAL»(ref-325302-S05347390512009071800000) , V-belt .
2. Use the ST to lock the crank pulley, and remove the crank pulley bolts. ST 499977400 CRANK PULLEY WRENCH
3. Remove the crank pulley.

1. Install the crank pulley.
2. Use the ST to lock the crank pulley, and attach the crank pulley bolts. ST 499977400 CRANK PULLEY WRENCH Clean the crankshaft thread using compressed air. Apply engine oil to the crank pulley bolt seat and thread. Tighten the bolts temporarily with tightening torque of 44 N.m (4.5 kgf-m, 32.5 ft-lb). Tighten the crank pulley bolts. Tightening torque: 130 N.m (13.3 kgf-m, 95.9 ft-lb)
3. Check that the tightening angle of the crank pulley bolt is 45° or more. Perform the following procedure when less than 45°. CAUTION: If the tightening angle of crank pulley bolt is less than 45°, the bolt is damaged. In this case, the bolt must be replaced. Replace the crank pulley bolts and clean them. Crank pulley bolt: Part No. 12369AA011 Clean the crankshaft thread using compressed air. Apply engine oil to the crank pulley bolt seat and thread. Tighten the bolts temporarily with tightening torque of 44 N.m (4.5 kgf-m, 32.5 ft-lb). Tighten the crank pulley bolts 45° to 60°. NOTE: Conduct the tightening procedures by confirming the turning angle of crank pulley bolt referring to the gauge indicated on timing belt cover.
4. Install the V-belt. Refer to «INSTALLATION»(ref-325302-S25313309332009071800000) , V-belt .

Note. Perform the work with the engine installed to body when replacing a single part.

1. Remove the secondary air pump. Refer to «REMOVAL»(ref-325337-S21607419822009071800000) , Secondary Air Pump .
2. Remove the V-belts. Refer to «REMOVAL»(ref-325302-S05347390512009071800000) , V-belt .
3. Remove the crank pulley. Refer to «REMOVAL»(ref-325302-S18189702652009071800000) , Crank Pulley .
4. Remove the timing belt cover LH (A).
5. Remove the timing belt cover RH (B).
6. Remove the front timing belt cover (C).

Scheme 340

1. Install the front timing belt cover (C). Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
2. Install the timing belt cover RH (B). Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
3. Install the timing belt cover LH (A). Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
4. Install the crank pulley. Refer to «INSTALLATION»(ref-325302-S32706224432009071800000) , Crank Pulley .
5. Install the V-belts. Refer to «INSTALLATION»(ref-325302-S25313309332009071800000) , V-belt .
6. Install the secondary air pump. Refer to «INSTALLATION»(ref-325337-S29788149002009071800000) , Secondary Air Pump .

Note. Perform the work with the engine installed to body when replacing a single part. For operation procedures, refer to "Timing Belt" in the PM article. Refer to TIMING BELT .

Scheme 341

Scheme 342

Scheme 343

Scheme 344

Scheme 345

1. Remove the V-belts. Refer to «REMOVAL»(ref-325302-S05347390512009071800000) , V-belt .
2. Remove the crank pulley. Refer to «REMOVAL»(ref-325302-S18189702652009071800000) , Crank Pulley .
3. Remove the timing belt cover. Refer to «REMOVAL»(ref-325302-S29663419372009071800000) , Timing Belt Cover .
4. If the alignment mark or arrow mark (which indicates the direction of rotation) 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 the timing belt cover and cylinder block. ST 499987500 CRANKSHAFT SOCKET Using white paint, put an alignment mark or an arrow mark on timing belts in relation to the crank sprocket and cam sprockets. Z 1 : 54.5 teeth Z 2 : 51 teeth Z 3 : 28 teeth
5. Remove the belt idler (A).
6. Remove the timing belt.

Scheme 346

Scheme 347

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

Scheme 348

Scheme 349

Scheme 350

1. Prepare for installation of the 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 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. Do not release the press pressure until stopper pin is completely inserted. Attach the automatic belt tension adjuster assembly to vertical pressing tool. Slowly push in the adjuster rod with a pressure of 165 N (16.8 kgf, 37.1 lb) or more until the adjuster rod is aligned with the stopper pin hole in the cylinder. With a 2 mm (0.08 in) dia. stopper pin or a 2 mm (nominal) dia. hex wrench inserted into the stopper pin hole in cylinder, secure the adjuster rod.
2. Install the automatic belt tension adjuster assembly. Tightening torque: 39 N.m (4.0 kgf-m, 28.8 ft-lb)
3. Install the belt idler No. 2. Tightening torque: 39 N.m (4.0 kgf-m, 28.8 ft-lb)
4. Install the belt idlers.

Tightening torque: 39 N.m (4.0 kgf-m, 28.8 ft-lb)

Scheme 351

Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)

Scheme 352

Scheme 353

Scheme 354

Scheme 355

Scheme 356

Scheme 357

Scheme 358

Scheme 359

Scheme 360

Scheme 361

Scheme 362

1. Prepare for installation of the automatic belt tension adjuster assembly. Refer to «AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER»(ref-325302-S07452139912009071800000) , INSTALLATION, Timing Belt .
2. Align the mark (A) on crank sprocket with the mark on oil pump cover at cylinder block.
3. Align the single line mark (A) on the exhaust cam sprocket RH with notch (B) on the timing belt cover.
4. Align the single line mark (A) on the intake cam sprocket RH with notch (B) on the timing belt cover. Make sure that the double lines (C) on the intake and exhaust camshaft sprockets are aligned.
5. Align the single line mark (A) on exhaust cam sprocket LH with notch (B) on the timing belt cover by turning the sprocket counterclockwise (as viewed from front of engine).
6. Align the single line mark (A) on intake cam sprocket LH with notch (B) on the timing belt cover by turning the sprocket clockwise (as viewed from front of engine). Make sure the double line marks (C) on the intake and exhaust cam sprockets are aligned.
7. 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. When the timing belts are not installed, four camshafts are held at the "zero-lift" position, where all cams on camshafts are not pushing down on the intake and exhaust valves. (Under this condition, all valves remain unlifted). When the camshafts are rotated to install the timing belts, #2 intake and #4 exhaust cam of camshaft LH are held, pushing their corresponding valves down. (Under this condition, these valves are held lifted). Camshaft RH are held so that their cams do not push the valves down. Camshafts LH must be rotated by the smallest possible angle from zero-lift position to where the timing belt can be installed, 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 upper figure. Doing this may cause both the intake and exhaust valves to lift simultaneously, resulting in mutual interference of heads.
8. Install the 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: If the timing belt slips by 1 or more teeth, the valve and piston may hit each other. Make sure that the direction of belt rotation is correct.
9. Install the belt idlers. Tightening torque: 39 N.m (4.0 kgf-m, 28.8 ft-lb) NOTE: Make sure that the marks on the timing belt and sprockets are aligned.
10. After ensuring that the marks on the timing belt and sprockets are aligned, remove the stopper pin from tensioner adjuster.
11. Install the timing belt cover. Refer to «INSTALLATION»(ref-325302-S41984258072009071800000) , Timing Belt Cover .
12. Install the crank pulley. Refer to «INSTALLATION»(ref-325302-S32706224432009071800000) , Crank Pulley .
13. Install the V-belts. Refer to «INSTALLATION»(ref-325302-S25313309332009071800000) , V-belt .

Note. Perform the work with the engine installed to body when replacing a single part.

1. Remove the V-belts. Refer to «REMOVAL»(ref-325302-S05347390512009071800000) , V-belt .
2. Remove the crank pulley. Refer to «REMOVAL»(ref-325302-S18189702652009071800000) , Crank Pulley .
3. Remove the timing belt cover. Refer to «REMOVAL»(ref-325302-S29663419372009071800000) , Timing Belt Cover .
4. Remove the timing belt. Refer to «REMOVAL»(ref-325302-S40767623722009071800000) , Timing Belt .
5. Remove the actuator cover of the intake cam sprocket.
6. Fasten the cam sprocket and remove from the cam shaft using ST.

ST 499207400 CAM SPROCKET WRENCH

Scheme 363

ST 499977500 CAM SPROCKET WRENCH

Scheme 364

1. Fasten the cam sprocket and install to the cam shaft using ST. NOTE: Do not confuse cam sprockets (LH) and (RH) during installation. ST 499207400 CAM SPROCKET WRENCH Tightening torque: Tighten to 30 N.m (3.1 kgf-m, 22.1 ft-lb) of torque, and then tighten further by 45° . ST 499977500 CAM SPROCKET WRENCH Tightening torque: Tighten to 30 N.m (3.1 kgf-m, 22.1 ft-lb) of torque, and then tighten further by 45° .
2. Attach the actuator cover of the intake cam sprocket. NOTE: Use new O-rings. Tightening torque: 3.4 N.m (0.3 kgf-m, 2.5 ft-lb)
3. Install the timing belt. Refer to «INSTALLATION»(ref-325302-S01610024312009071800000) , Timing Belt .
4. Install the timing belt cover. Refer to «INSTALLATION»(ref-325302-S41984258072009071800000) , Timing Belt Cover .
5. Install the crank pulley. Refer to «INSTALLATION»(ref-325302-S32706224432009071800000) , Crank Pulley .
6. Install the V-belts. Refer to «INSTALLATION»(ref-325302-S25313309332009071800000) , V-belt .

Note. Perform the work with the engine installed to body when replacing a single part.

1. Remove the V-belts. Refer to «REMOVAL»(ref-325302-S05347390512009071800000) , V-belt .
2. Remove the crank pulley. Refer to «REMOVAL»(ref-325302-S18189702652009071800000) , Crank Pulley .
3. Remove the timing belt cover. Refer to «REMOVAL»(ref-325302-S29663419372009071800000) , Timing Belt Cover .
4. Remove the timing belt. Refer to «REMOVAL»(ref-325302-S40767623722009071800000) , Timing Belt .
5. Remove the crank sprocket.

Scheme 365

1. Install the crank sprocket.
2. Install the timing belt. Refer to «INSTALLATION»(ref-325302-S01610024312009071800000) , Timing Belt .
3. Install the timing belt cover. Refer to «INSTALLATION»(ref-325302-S41984258072009071800000) , Timing Belt Cover .
4. Install the crank pulley. Refer to «INSTALLATION»(ref-325302-S32706224432009071800000) , Crank Pulley .
5. Install the V-belts. Refer to «INSTALLATION»(ref-325302-S25313309332009071800000) , V-belt .

Note. Perform the work with the engine installed to body when replacing a single part. Refer to "Valve Clearance" for preparation. Refer to INSPECTION , Valve Clearance .

Scheme 366

Scheme 367

Scheme 368

Scheme 369

Scheme 370

Scheme 371

Scheme 372

1. Remove the V-belts. Refer to «REMOVAL»(ref-325302-S05347390512009071800000) , V-belt .
2. Remove the crank pulley. Refer to «REMOVAL»(ref-325302-S18189702652009071800000) , Crank Pulley .
3. Remove the timing belt cover. Refer to «REMOVAL»(ref-325302-S29663419372009071800000) , Timing Belt Cover .
4. Remove the timing belt. Refer to «REMOVAL»(ref-325302-S40767623722009071800000) , Timing Belt .
5. Remove the cam sprocket. Refer to «REMOVAL»(ref-325302-S13116246022009071800000) , Cam Sprocket .
6. Disconnect the oil flow control solenoid valve connector.
7. Remove the timing belt cover No. 2 LH.
8. Remove the timing belt cover No. 2 RH. NOTE: Do not damage or lose the seal rubber when removing the timing belt covers.
9. Remove the tensioner bracket.
10. Remove the ignition coil. Refer to «REMOVAL»(ref-325338-S36569430992009071800000) , Ignition Coil .
11. Disconnect the PCV hose from the rocker cover. NOTE: For the PCV hose affixed with the clamp, fit the depression in the ST with the protrusion of the clamp as shown in the figure below, unlock the clamp and disconnect. ST 18353AA000 CLAMP PLIERS
12. Remove the rocker cover and gasket.
13. Remove the oil pipe.
14. Loosen the front camshaft cap upper area and intake camshaft cap bolts equally, a little at a time in alphabetical order as shown in the figure.
15. Loosen the front camshaft cap lower area and exhaust camshaft cap bolts equally, a little at a time in alphabetical order as shown in the figure.
16. Remove the front camshaft cap.
17. Remove the intake camshaft caps and intake camshaft.
18. Remove the exhaust camshaft caps and exhaust camshaft. NOTE: Arrange camshaft caps in order so that they can be installed in their original positions.
19. Remove the oil seal. NOTE: Do not scratch the journal surface when removing the oil seal.
20. Similarly, remove the camshaft RH and related parts.

Scheme 373

Scheme 374

Scheme 375

Scheme 376

Scheme 377

Scheme 378

Scheme 379

1. Install the camshaft. Apply engine oil to the cylinder head at camshaft journal 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 lobe. NOTE: Set the camshaft to the position shown in the figure. When set at the position shown in the figure, it is not necessary to rotate camshaft RH when installing the timing belt, but it is necessary to rotate camshaft LH slightly. Intake camshaft LH: Rotate 80° clockwise . Exhaust camshaft LH: Rotate 45° counterclockwise .
2. Install the camshaft cap. Apply small amount of liquid gasket to the mating surface of cap. NOTE: Install within 5 min. after applying liquid gasket. 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 1217G (Part No. K0877Y0100) or equivalent Apply a thin coat of engine oil to the cap journal surface, and install the camshaft cap to the camshaft. Gradually tighten the camshaft cap in at least two steps, in alphabetical order shown in the figure, and then tighten to the specified torque. Tightening torque: T1: 9.75 N.m (1.0 kgf-m, 7.2 ft-lb) T2: 20 N.m (2.0 kgf-m, 14.8 ft-lb) After tightening the camshaft cap, ensure the camshaft rotates only slightly while holding it at base circle.
3. Apply a coat of engine oil to the camshaft oil seal periphery and oil seal lips, then install the oil seal on the camshaft using ST1 and ST2. NOTE: Use a new oil seal. ST1 499587600 OIL SEAL INSTALLER ST2 499597200 OIL SEAL GUIDE
4. 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)
5. Similarly, install the parts on right-hand side.
6. Install the tensioner bracket. Tightening torque: 24.5 N.m (2.5 kgf-m, 18.1 ft-lb)
7. Install the timing belt cover No. 2 RH. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
8. Install the timing belt cover No. 2 LH. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
9. Install the cam sprocket. Refer to «INSTALLATION»(ref-325302-S41439610452009071800000) , Cam Sprocket .
10. Install the timing belt. Refer to «INSTALLATION»(ref-325302-S01610024312009071800000) , Timing Belt .
11. Adjust the valve clearance. Refer to «ADJUSTMENT»(ref-325302-S17591177352009071800000) , Valve Clearance .
12. Install the rocker cover. Install the rocker cover gasket to the rocker cover. (Outer periphery and ignition coil section) NOTE: Use a new rocker cover gasket. Apply liquid gasket to the specified point of the cylinder head. NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent 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 in alphabetical order. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
13. Connect the PCV hose to the rocker cover. NOTE: For the PVC hose clamp, use a new clamp. Sandwich the protruding part of the clamp with the ST and lock the clamp. ST 18353AA000 CLAMP PLIERS
14. Connect the connector to the oil flow control solenoid valve.
15. Attach the ignition coil. Refer to «INSTALLATION»(ref-325338-S19932529392009071800000) , Ignition Coil .
16. Install the timing belt cover. Refer to «INSTALLATION»(ref-325302-S41984258072009071800000) , Timing Belt Cover .
17. Install the crank pulley. Refer to «INSTALLATION»(ref-325302-S32706224432009071800000) , Crank Pulley .
18. Install the V-belts. Refer to «INSTALLATION»(ref-325302-S25313309332009071800000) , V-belt .

Scheme 380

Scheme 381

Scheme 382

Scheme 383

1. Measure the bend, and repair or replace if necessary. Service limit: 0.020 mm (0.0079 in) or less
2. Check the journal for damage and wear. Replace if faulty.
3. Check the cutout portion used for camshaft sensor for damage. Replace if faulty.
4. Measure the outside diameter of camshaft journal. If the journal diameter is not within the standard value, check the oil clearance. CAMSHAFT JOURNAL REFERENCE Camshaft journal Front Center, rear Standard mm (in) 37.946 - 37.963 (1.4939 - 1.4946) 29.946 - 29.963 (1.1790 - 1.1796)
5. Measure the camshaft journal oil clearance. Clean the camshaft cap and cylinder head camshaft journal. Place the camshaft on the cylinder head. (Without installing the valve lifter) Place a plastigauge across each camshaft journals. Gradually tighten the camshaft cap in at least two steps, in alphabetical order shown in the figure, and then tighten to the specified torque. Do not turn the camshaft. Tightening torque: T1: 9.75 N.m (1.0 kgf-m, 7.2 ft-lb) T2: 20 N.m (2.0 kgf-m, 14.8 ft-lb) Remove the camshaft cap. Measure the widest point of the plastigauge on each journal. If oil clearance exceeds the standard, 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) Completely remove the plastigauge.
6. Check the cam face condition; remove the minor faults by grinding with oil stone. Measure the cam height H. If it exceeds the standard or offset wear occurs, replace it. 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) Cam base circle diameter A: 37.0 mm (1.457 in)
7. Measure the thrust clearance of camshaft with setting the dial gauge at end of camshaft. If the thrust clearance is not within the standard or there is offset wear, replace the camshaft caps and cylinder head as a set. If necessary replace the camshaft. Standard: 0.068 - 0.116 mm (0.0027 - 0.0047 in)

Note. Perform the work with the engine installed to body when replacing a single part. Refer to "Valve Clearance" for preparation. Refer to INSPECTION , Valve Clearance .

Scheme 384

1. Remove the V-belts. Refer to «REMOVAL»(ref-325302-S05347390512009071800000) , V-belt .
2. Remove the intake manifold. Refer to «REMOVAL»(ref-325306-S22805286222009071800000) , Intake Manifold .
3. Remove the crank pulley. Refer to «REMOVAL»(ref-325302-S18189702652009071800000) , Crank Pulley .
4. Remove the timing belt cover. Refer to «REMOVAL»(ref-325302-S29663419372009071800000) , Timing Belt Cover .
5. Remove the timing belt. Refer to «REMOVAL»(ref-325302-S40767623722009071800000) , Timing Belt .
6. Remove the cam sprocket. Refer to «REMOVAL»(ref-325302-S13116246022009071800000) , Cam Sprocket .
7. Remove the bolt which installs the A/C compressor bracket on cylinder head.
8. Remove the secondary air combination valve. Refer to «REMOVAL»(ref-325337-S19075787532009071800000) , Secondary Air Combination Valve .
9. Remove the camshaft. Refer to «REMOVAL»(ref-325302-S00849469062009071800000) , Camshaft .
10. Remove the oil level gauge guide. (LH side only)
11. Remove the cylinder head bolts in alphabetical order shown in the figure. NOTE: Leave the bolts (A) and (D) engaged by three or four threads to prevent the cylinder head from falling.
12. While tapping the cylinder head with a plastic hammer, separate it from cylinder block. Remove the bolts (A) and (D) to remove cylinder head.
13. Remove the cylinder head gasket. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block.
14. Similarly, remove the right side cylinder head.

Scheme 385

1. Install the cylinder head and gaskets on cylinder block. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block. NOTE: Use a new cylinder head gasket.
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, 21.4 ft-lb) in alphabetical order. Further tighten all bolts to 69 N.m (7.0 kgf-m, 50.9 ft-lb) in alphabetical order. Loosen all the bolts by 180° in the reverse order of installing, and loosen them further by 180°. Tighten all bolts to 49 N.m (5.0 kgf-m, 36.1 ft-lb) in alphabetical order. Tighten all bolts by 80 to 90° in alphabetical order. Tighten all bolts by 40 to 45° in alphabetical order. CAUTION: The tightening angle of the bolt should not exceed 45°. Further tighten the bolts (A) and (B) by 40 - 45°. CAUTION: Make sure the total "re-tightening angle" of the step (7) and (8) does not exceed 90°.
3. Install the oil level gauge guide. (LH side only) Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
4. Install the camshaft. Refer to «INSTALLATION»(ref-325302-S19247684902009071800000) , Camshaft .
5. Install the A/C compressor bracket on cylinder head. Tightening torque: 36 N.m (3.7 kgf-m, 26.6 ft-lb)
6. Install the secondary air combination valve. Refer to «INSTALLATION»(ref-325337-S18458685652009071800000) , Secondary Air Combination Valve .
7. Install the cam sprocket. Refer to «INSTALLATION»(ref-325302-S41439610452009071800000) , Cam Sprocket .
8. Install the timing belt. Refer to «INSTALLATION»(ref-325302-S01610024312009071800000) , Timing Belt .
9. Adjust the valve clearance. Refer to «ADJUSTMENT»(ref-325302-S17591177352009071800000) , Valve Clearance .
10. Install the rocker cover. Install the rocker cover gasket to the rocker cover. (Outer periphery and ignition coil section) NOTE: Use a new rocker cover gasket. Apply liquid gasket to the specified point of the cylinder head. NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent 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 in alphabetical order. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
11. Install the timing belt cover. Refer to «INSTALLATION»(ref-325302-S41984258072009071800000) , Timing Belt Cover .
12. Install the crank pulley. Refer to «INSTALLATION»(ref-325302-S32706224432009071800000) , Crank Pulley .
13. Install the intake manifold. Refer to «INSTALLATION»(ref-325306-S42927947652009071800000) , Intake Manifold .
14. Install the V-belts. Refer to «INSTALLATION»(ref-325302-S25313309332009071800000) , V-belt .

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

Scheme 386

Scheme 387

Scheme 388

Scheme 389

Scheme 390

Scheme 391

Scheme 392

Scheme 393

Scheme 394

1. Remove the V-belts. Refer to «REMOVAL»(ref-325302-S05347390512009071800000) , V-belt .
2. Remove the intake manifold. Refer to «REMOVAL»(ref-325306-S22805286222009071800000) , Intake Manifold .
3. Remove the crank pulley. Refer to «REMOVAL»(ref-325302-S18189702652009071800000) , Crank Pulley .
4. Remove the timing belt cover. Refer to «REMOVAL»(ref-325302-S29663419372009071800000) , Timing Belt Cover .
5. Remove the timing belt. Refer to «REMOVAL»(ref-325302-S40767623722009071800000) , Timing Belt .
6. Remove the cam sprocket. Refer to «REMOVAL»(ref-325302-S13116246022009071800000) , Cam Sprocket .
7. Remove the crank sprocket. Refer to «REMOVAL»(ref-325302-S08119963932009071800000) , Crank Sprocket .
8. Remove the generator and A/C compressor with their brackets.
9. Remove the camshaft. Refer to «REMOVAL»(ref-325302-S00849469062009071800000) , Camshaft .
10. Remove the cylinder head. Refer to «REMOVAL»(ref-325302-S16307656822009071800000) , Cylinder Head .
11. Remove the drive plate. Using the ST, lock the crankshaft. ST 498497100 CRANKSHAFT STOPPER
12. Remove the oil separator cover.
13. Remove the water by-pass pipe for heater.
14. Remove the oil filter. Refer to «REMOVAL»(ref-325339-S18786058012009071800000) , Engine Oil Filter .
15. Remove the water pump. Refer to «REMOVAL»(ref-325304-S16639600752009071800000) , Water Pump .
16. Remove the bolts which install oil pump onto cylinder block. NOTE: When disassembling and checking the oil pump, loosen the relief valve plug before removing the oil pump.
17. Remove the oil pump from cylinder block using a flat tip screwdriver. CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump.
18. Remove the front oil seal from the oil pump.
19. Remove the oil pan. Set the part so that the cylinder block LH is on the upper side. Remove the bolts which secure oil pan to cylinder block. Insert an oil pan cutter blade between cylinder block-to-oil pan clearance and remove the oil pan. CAUTION: Do not use a screwdriver or similar tools in place of oil pan cutter.
20. Remove the oil strainer.
21. Remove the baffle plate.
22. Remove the water tank pipe assembly.
23. Remove the water pipe assembly.
24. Remove the service hole plugs using a hexagon wrench [14 mm].
25. Remove the service hole cover.
26. Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove the piston snap ring through service hole of #1 and #2 cylinders.
27. 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.
28. Similarly remove the piston pins from #3 and #4 pistons.
29. Remove the cylinder block connecting bolt on the RH side.
30. Loosen the cylinder block connecting bolt on the LH side by 2-3 turns.
31. Set the part so that the cylinder block LH is on the upper side, and remove the cylinder block connecting bolt.
32. Separate cylinder block LH and RH. NOTE: When separating the cylinder block, do not allow the connecting rod to fall and damage the cylinder block.
33. Remove the rear oil seal.
34. Remove the crankshaft together with connecting rod.
35. Remove the crankshaft bearings from cylinder block using a hammer handle. NOTE: Push the opposite side of the crank shaft bearing locking lip to remove. Be careful not to confuse the crankshaft bearing combination.
36. Draw out each piston from cylinder block using wooden bar or hammer handle.

Note. Be careful not to confuse the original combination of piston and cylinder.

Scheme 395

Scheme 396

Scheme 397

Scheme 398

Scheme 399

Scheme 400

Scheme 401

Scheme 402

Scheme 403

Scheme 404

Scheme 405

Scheme 406

Scheme 407

Scheme 408

Scheme 409

Scheme 410

Scheme 411

Scheme 412

Scheme 413

Scheme 414

Scheme 415

Scheme 416

Scheme 417

Scheme 418

Scheme 419

Scheme 420

1. Remove oil on the mating surface of cylinder block before installation. Apply a coat of engine oil to the bearing and crankshaft journal.
2. Position the crankshaft and O-ring on cylinder block RH. NOTE: Use new O-rings.
3. Apply liquid gasket to the mating surfaces of cylinder block RH, and position cylinder block LH. NOTE: Install within 5 min. after applying liquid gasket. Do not allow liquid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent
4. Apply a coat of engine oil to the washer and bolt thread. NOTE: Use a new seal washer.
5. Tighten the 10 mm cylinder block connecting bolts on LH side (A - D) in alphabetical sequence. Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb)
6. Tighten the 10 mm cylinder block connecting bolts on RH side (E - J) in alphabetical sequence. Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb)
7. Tighten the LH side cylinder block connecting bolts (A - D) further in alphabetical order. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
8. Tighten the RH side cylinder block connecting bolts (E - J) further in alphabetical order. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
9. Tighten the LH side cylinder block connecting bolts (A - D) further in alphabetical order. (A), (C): Angle tightening Tightening angle: 90° (B), (D): Torque tightening Tightening torque: 40 N.m (4.1 kgf-m, 29.5 ft-lb)
10. Tighten the RH side cylinder block connecting bolts (E - J) further in alphabetical order. Tightening angle: 90°
11. Tighten the 8 mm and 6 mm cylinder block connecting bolts on the LH side (A - H) in alphabetical order. Tightening torque: (A) - (G): 25 N.m (2.5 kgf-m, 18.4 ft-lb) (H): 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
12. Apply a coat of engine oil to the oil seal periphery, then install the rear oil seal using ST1 and ST2. NOTE: Use a new rear oil seal. 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 the top ring gap.
15. Position the upper rail gap at (C) in the figure.
16. Align the upper rail spin stopper (E) to the side hole (D) on the piston.
17. Position the expander gap at (F) in the figure on the 180° opposite direction of (C).
18. Set the lower rail gap at position (G), located 120° clockwise from (C). NOTE: Make sure ring gaps do not face the same direction. Make sure ring gaps are not within the piston skirt area.
19. Install the snap ring. Before positioning the piston on the cylinder block, attach the snap ring in the service hole of the cylinder block, and the piston hole on the opposite side. NOTE: Use new snap rings.
20. Install piston. Set the parts so that the #1 and #2 cylinders are on the upper side. 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: Face the piston front mark towards the front of the engine.
21. Install piston pin. Apply a coat of engine oil to ST3. Insert ST3 into the service hole to align the piston pin hole and the connecting rod small end. ST3 499017100 PISTON PIN GUIDE Apply a coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole. Install the snap ring. NOTE: Use new snap rings. Apply liquid gasket to the threaded portion of the service hole plug. Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent Install the water pump and gasket. NOTE: Use a new gasket. Tightening torque: 70 N.m (7.1 kgf-m, 51.6 ft-lb) Set the parts so that the #3 and #4 cylinders are on the upper side. Following the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins. Install the service hole cover. NOTE: Use new O-rings. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
22. Install the water pipe assembly. NOTE: Use new O-rings. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
23. Install the water tank pipe assembly. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
24. Install the baffle plate. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
25. Install the oil strainer. NOTE: Use new O-rings. Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb)
26. Tighten the oil strainer stay together with the baffle plate. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
27. Apply liquid gasket to the mating surfaces of oil pan, and install the oil pan. NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
28. Apply liquid gasket to the mating surface of oil separator cover and the threaded portion of bolt (A) shown in the figure (when reusing the bolt), and then install the oil separator cover. NOTE: Install within 5 min. after applying liquid gasket. Use new oil separator cover. Liquid gasket: Mating surface THREE BOND 1217G (Part No. K0877Y0100) or equivalent Bolt thread (A) (when reusing the bolt) THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
29. Install the drive plate. Using the ST, lock the crankshaft. ST 498497100 CRANKSHAFT STOPPER Tightening torque: 72 N.m (7.3 kgf-m, 53.1 ft-lb)
30. Install the oil pump. Using the ST, install the front oil seal. ST 499587100 OIL SEAL INSTALLER NOTE: Use a new front oil seal. Apply liquid gasket to the matching surface of oil pump. NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Apply a coat of engine oil to the inside of oil seal. Install the oil pump to cylinder block. Be careful not to damage the oil seal during installation. NOTE: Make sure the oil seal lip is not folded. Align the flat surface of oil pump's inner rotor with crankshaft before installation. Use new O-rings and oil seals. Do not forget to install the O-ring. Apply liquid gasket to the three bolts thread shown in figure, (when reusing bolts) Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
31. Install the water pump and gasket. NOTE: When installing the water pump, tighten bolts in two stages in alphabetical sequence as shown in the figure. Use a new gasket. Tightening torque: First: 12 N.m (1.2 kgf-m, 8.9 ft-lb) Second: 12 N.m (1.2 kgf-m, 8.9 ft-lb)
32. Install the water by-pass pipe for heater. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
33. Install the oil filter. Refer to «INSTALLATION»(ref-325339-S22189989642009071800000) , Engine Oil Filter .
34. Install the cylinder head. Refer to «INSTALLATION»(ref-325302-S42185546262009071800000) , Cylinder Head .
35. Install the camshaft. Refer to «INSTALLATION»(ref-325302-S19247684902009071800000) , Camshaft .
36. Install the generator and A/C compressor with their brackets. Tightening torque: 36 N.m (3.7 kgf-m, 26.6 ft-lb)
37. Install the crank sprocket. Refer to «INSTALLATION»(ref-325302-S03512802502009071800000) , Crank Sprocket .
38. Install the cam sprocket. Refer to «INSTALLATION»(ref-325302-S41439610452009071800000) , Cam Sprocket .
39. Install the timing belt. Refer to «INSTALLATION»(ref-325302-S01610024312009071800000) , Timing Belt .
40. Adjust the valve clearance. Refer to «ADJUSTMENT»(ref-325302-S17591177352009071800000) , Valve Clearance .
41. Install the rocker cover. Install the rocker cover gasket to the rocker cover. (Outer periphery and ignition coil section) NOTE: Use a new rocker cover gasket. Apply liquid gasket to the specified point of the cylinder head. NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent 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 in alphabetical order. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
42. Install the timing belt cover. Refer to «INSTALLATION»(ref-325302-S41984258072009071800000) , Timing Belt Cover .
43. Install the crank pulley. Refer to «INSTALLATION»(ref-325302-S32706224432009071800000) , Crank Pulley .
44. Install the intake manifold. Refer to «INSTALLATION»(ref-325306-S42927947652009071800000) , Intake Manifold .
45. Install the V-belts. Refer to «INSTALLATION»(ref-325302-S25313309332009071800000) , V-belt .

Scheme 421

1. Remove the connecting rod cap.
2. Remove the connecting rod bearing. NOTE: Keep the removed connecting rods, connecting rod caps and bearings in order so that they are kept in their original combinations/groups, and not mixed together.
3. Remove the piston rings using 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 snap ring.

Scheme 422

1. Apply engine oil to the surface of the connecting rod bearings, and attach the connecting rod bearings to the connecting rods and connecting rod caps.
2. Position each connecting rod with their side marks facing forward, and install.
3. Attach the connecting rod cap, and tighten with the connecting rod bolt. Make sure the arrow mark on connecting rod cap facing 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 bolts, apply oil on the threads. Tightening torque: 52 N.m (5.3 kgf-m, 38.4 ft-lb)
4. Install the oil ring upper rail, expander and lower rail by hand.
5. Install the second ring and top ring using piston ring expander.

Note. Assemble so that the piston ring mark "R" faces the top side of the piston.