Engine Mechanical (H4SO): Removal & Installation Subaru Forester SH

REMOVAL

1. Remove the engine unit. Refer to «REMOVAL»(ref-325301-S04923769772009071800000) , Engine Assembly .
2. Remove the engine mounting from engine assembly.

INSTALLATION

Install in the reverse order of removal.

Tightening torque

Engine mounting

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

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

Scheme 114

1. Remove the V-belt cover.
2. Remove the air intake duct (rear). Refer to «REMOVAL»(ref-325315-S30653479982009071800000) , Air Intake Duct .
3. Loosen the bolt (A).
4. Loosen the slider bolt (B).
5. Remove the front side belt (C).

Scheme 115

1. Remove the front side belts. Refer to «FRONT SIDE BELT»(ref-325301-S19102835222009071800000) , REMOVAL, V-belt .
2. Cut the rear side belt with a wire cutter, etc., and discard.

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

Scheme 116

1. Remove the V-belts. Refer to «REMOVAL»(ref-325301-S15291069492009071800000) , V-belt .
2. Use the ST to lock the crank pulley, and remove the crank pulley bolts. ST 499977100 CRANK PULLEY WRENCH (MT model) ST 499977400 CRANK PULLEY WRENCH (AT model)
3. Remove the crank pulley.

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

Scheme 117

1. Remove the V-belts. Refer to «REMOVAL»(ref-325301-S15291069492009071800000) , V-belt .
2. Remove the crank pulley. Refer to «REMOVAL»(ref-325301-S42579091412009071800000) , Crank Pulley .
3. Remove the timing belt cover LH.
4. Remove the front timing belt cover.

Scheme 118

1. Install the front timing belt cover. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
2. Install the timing belt cover LH. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
3. Install the crank pulley. Refer to «INSTALLATION»(ref-325301-S27405060002009071800000) , Crank Pulley .
4. Install the V-belts. Refer to «INSTALLATION»(ref-325301-S10873526442009071800000) , V-belt .

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 .

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Scheme 125

1. Remove the V-belts. Refer to «REMOVAL»(ref-325301-S15291069492009071800000) , V-belt .
2. Remove the crank pulley. Refer to «REMOVAL»(ref-325301-S42579091412009071800000) , Crank Pulley .
3. Remove the timing belt cover. Refer to «REMOVAL»(ref-325301-S32499370542009071800000) , Timing Belt Cover .
4. Remove the timing belt guide. (MT model)
5. 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. Use the ST to turn crankshaft. Align the mark (a) of sprocket to the cylinder block notch (b), and then ensure the right side cam sprocket mark (c), cam cap and cylinder head matching surface (d) or left side cam sprocket mark (e), timing belt cover notch (f) are properly adjusted. 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 : 46.8 teeth Z 2 : 43.7 teeth
6. Remove the belt idler (A).
7. Remove the belt idler (B).
8. Remove the timing belt.

Scheme 126

Scheme 127

1. Remove the belt idler No. 1.
2. Remove the automatic belt tension adjuster assembly.

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Scheme 130

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 lb). Push in the adjuster rod to the end face of the cylinder. However, do not push in 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. 1. Tightening torque: 39 N.m (4.0 kgf-m, 28.8 ft-lb)

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1. Prepare for installation of the automatic belt tension adjuster assembly. Refer to «AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER»(ref-325301-S22898930842009071800000) , INSTALLATION, Timing Belt .
2. Align the mark (A) on crank sprocket with the mark on oil pump cover at cylinder block.
3. Turn the camshaft sprocket No. 2 using ST1, and turn the camshaft sprocket No. 1 using ST2 so that their alignment marks (A) come to top positions. ST1 18231AA010 CAM SPROCKET WRENCH NOTE: CAM SPROCKET WRENCH (499207100) can also be used. ST2 499207400 CAM SPROCKET WRENCH
4. While aligning the alignment mark (B) on timing belt with the mark (A) on sprockets, position the timing belt properly.
5. Install the belt idler (B). Tightening torque: 39 N.m (4.0 kgf-m, 28.8 ft-lb)
6. Install the belt idler (A). Tightening torque: 39 N.m (4.0 kgf-m, 28.8 ft-lb)
7. After ensuring the marks on timing belt and camshaft sprockets are aligned, remove the stopper pin from belt tension adjuster.
8. Install the timing belt guide. (MT model) Temporarily tighten the bolts mounting the timing belt guide. Check and adjust the clearance between timing belt and timing belt guide by using thickness gauge. Clearance: 1.0±0.5 mm (0.039±0.020 in) Tighten the bolts mounting the timing belt guide. Tightening torque: 9.75 N.m (1.0 kgf-m, 7.2 ft-lb)
9. Install the timing belt cover. Refer to «INSTALLATION»(ref-325301-S08843078112009071800000) , Timing Belt Cover .
10. Install the crank pulley. Refer to «INSTALLATION»(ref-325301-S27405060002009071800000) , Crank Pulley .
11. Install the V-belts. Refer to «INSTALLATION»(ref-325301-S10873526442009071800000) , V-belt .

Scheme 138

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. CAUTION: Be careful not to let oil, grease or coolant contact the timing belt. Remove quickly and thoroughly if this happens. Do not bend the timing belt sharply. In radial diameter h: 60 mm (2.36 in) or more

Scheme 139

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 at rod's oil seal 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 lb) is applied to it. This is to check adjuster rod stiffness.
3. If the adjuster rod is not stiff and moves freely when applying 165 N (16.8 kgf, 37.1 lb), 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 lb) to it. Check the adjuster rod stiffness. If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new 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 the adjuster rod gradually taking three minutes or more. Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lb). Push in the adjuster rod to the end face of the cylinder. However, do not push in 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 the body. If it is not within specified range, replace with new part. Amount of rod protrusion H: 5.2 - 6.2 mm (0.204 - 0.244 in)

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

Scheme 140

Scheme 141

1. Remove the V-belts. Refer to «REMOVAL»(ref-325301-S15291069492009071800000) , V-belt .
2. Remove the crank pulley. Refer to «REMOVAL»(ref-325301-S42579091412009071800000) , Crank Pulley .
3. Remove the timing belt cover. Refer to «REMOVAL»(ref-325301-S32499370542009071800000) , Timing Belt Cover .
4. Remove the timing belt. Refer to «REMOVAL»(ref-325301-S23657586352009071800000) , Timing Belt .
5. Remove the camshaft position sensor. Refer to «REMOVAL»(ref-325305-S14572555632009071800000) , Camshaft Position Sensor .
6. Fasten the cam sprocket and remove from the cam shaft using ST. ST 18231AA010 CAM SPROCKET WRENCH NOTE: CAM SPROCKET WRENCH (499207100) can also be used. ST 499207400 CAM SPROCKET WRENCH

1. Fasten the cam sprocket and install to the cam shaft using ST. NOTE: Do not confuse left and right side cam sprockets during installation. They should be distinguished by the L or R indication. ST 18231AA010 CAM SPROCKET WRENCH NOTE: CAM SPROCKET WRENCH (499207100) can also be used. Tightening torque: 78 N.m (8.0 kgf-m, 57.5 ft-lb) ST 499207400 CAM SPROCKET WRENCH Tightening torque: 78 N.m (8.0 kgf-m, 57.5 ft-lb)
2. Install the camshaft position sensor. Refer to «INSTALLATION»(ref-325305-S29737598102009071800000) , Camshaft Position Sensor .
3. Install the timing belt. Refer to «INSTALLATION»(ref-325301-S23320513242009071800000) , Timing Belt .
4. Install the timing belt cover. Refer to «INSTALLATION»(ref-325301-S08843078112009071800000) , Timing Belt Cover .
5. Install the crank pulley. Refer to «INSTALLATION»(ref-325301-S27405060002009071800000) , Crank Pulley .
6. Install the V-belts. Refer to «INSTALLATION»(ref-325301-S10873526442009071800000) , V-belt .

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

Scheme 142

1. Remove the V-belts. Refer to «REMOVAL»(ref-325301-S15291069492009071800000) , V-belt .
2. Remove the crank pulley. Refer to «REMOVAL»(ref-325301-S42579091412009071800000) , Crank Pulley .
3. Remove the timing belt cover. Refer to «REMOVAL»(ref-325301-S32499370542009071800000) , Timing Belt Cover
4. Remove the timing belt. Refer to «REMOVAL»(ref-325301-S23657586352009071800000) , Timing Belt .
5. Remove the crank sprocket.

1. Install the crank sprocket.
2. Install the timing belt. Refer to «INSTALLATION»(ref-325301-S23320513242009071800000) , Timing Belt .
3. Install the timing belt cover. Refer to «INSTALLATION»(ref-325301-S08843078112009071800000) , Timing Belt Cover .
4. Install the crank pulley. Refer to «INSTALLATION»(ref-325301-S27405060002009071800000) , Crank Pulley .
5. Install the V-belts. Refer to «INSTALLATION»(ref-325301-S10873526442009071800000) , V-belt .

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

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1. Remove the high tension cord.
2. Disconnect the PCV hose and remove the rocker cover. NOTE: Fit the depression in the ST with the protrusion of the clamp as shown in the figure below, and unlock the clamp. ST 18353AA000 CLAMP PLIERS
3. Remove the valve rocker assembly. Use the ST to rotate the spring stopper in the direction of the arrow to remove it from adjuster pin. ST 18258AA000 SPRING INSTALLER Remove the bolts (a) through (j) in alphabetical sequence. NOTE: Leave two or three threads of bolts (i) and (j) engaged in order to retain the valve rocker assembly. Remove the valve rocker assembly. NOTE: Set the ST in the position shown in the figure to remove the intake valve rocker assembly. ST 18354AA000 VALVE ROCKER HOLDER

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Scheme 150

1. Install the valve rocker assembly. Temporarily tighten the bolts equally in alphabetical order as shown in the figure. NOTE: Do not temporarily tighten the bolts (i) and (j). Set the ST in the position shown in the figure to mount the intake valve rocker assembly. ST 18354AA000 VALVE ROCKER HOLDER Tighten the bolts (a) through (h) to specified torque. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb) Tighten the bolts (i) through (j) to specified torque. Tightening torque: 6 N.m (0.6 kgf-m, 4.4 ft-lb) Use the ST to rotate the spring stopper in the direction of the arrow to fasten the adjuster pin. ST 18258AA000 SPRING INSTALLER
2. Adjust the valve clearance. Refer to «ADJUSTMENT»(ref-325301-S24451996572009071800000) , Valve Clearance .
3. Install the rocker cover. Install the rocker cover gasket to the rocker cover. NOTE: Use a new rocker cover gasket. Temporarily tighten the bolts in alphabetical sequence as shown in figure, then tighten the bolt in 2 steps. Tightening torque: 1st 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 2nd (only (a) and (b) are tightened) 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) RH side LH side
4. Connect the PCV hose. NOTE: For the PCV hose clamp, use a new clamp. Sandwich the protruding part of the clamp with the ST and lock the clamp. ST 18353AA000 CLAMP PLIERS
5. Install the high tension cord.
6. Install the timing belt cover. Refer to «INSTALLATION»(ref-325301-S08843078112009071800000) , Timing Belt Cover .

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

Scheme 151

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Scheme 155

1. Remove the V-belts. Refer to «REMOVAL»(ref-325301-S15291069492009071800000) , V-belt .
2. Remove the crank pulley. Refer to «REMOVAL»(ref-325301-S42579091412009071800000) , Crank Pulley .
3. Remove the timing belt cover. Refer to «REMOVAL»(ref-325301-S32499370542009071800000) , Timing Belt Cover .
4. Remove the timing belt. Refer to «REMOVAL»(ref-325301-S23657586352009071800000) , Timing Belt .
5. Remove the cam sprocket. Refer to «REMOVAL»(ref-325301-S13353465022009071800000) , Cam Sprocket .
6. Remove the timing belt cover No. 2 LH.
7. Remove the timing belt cover No. 2 RH. NOTE: Do not damage or lose the seal rubber when removing the timing belt covers.
8. Remove the tensioner bracket.
9. Remove the camshaft position sensor support. (LH side only)
10. Remove the valve rocker assembly. Refer to «REMOVAL»(ref-325301-S06727693812009071800000) , Valve Rocker Assembly .
11. Remove the camshaft cap. Remove the bolts (a) and (b) in alphabetical sequence. Equally loosen the bolts (c) through (j) all the way in alphabetical sequence. Remove the bolts (k) through (p) in alphabetical sequence using ST. ST 499497000 TORX PLUS® Remove the camshaft cap.
12. Remove the camshaft.
13. Remove the oil seal.
14. Remove the plug from rear side of camshaft. CAUTION: Do not scratch the journal surface when removing the oil seal.
15. Similarly, remove the camshaft RH and related parts.

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1. Apply a thin coat of engine oil to camshaft journals, and install the camshaft.
2. Install the camshaft cap. Apply liquid gasket to the mating surfaces of camshaft cap. NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent NOTE: Apply a coat of liquid gasket of 3 mm (0.12 in) in diameter (A) along the edge (B) of camshaft cap (C) mating surface. Temporarily tighten the bolts (a) through (d) in alphabetical sequence. Install the valve rocker assembly. Refer to «INSTALLATION»(ref-325301-S21201125512009071800000) , Valve Rocker Assembly . Tighten the TORX® bolts (e) through (j) in alphabetical sequence using the ST. ST 499497000 TORX PLUS® Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) Tighten the bolts (k) through (r) in alphabetical sequence. Tightening torque: 9.75 N.m (1.0 kgf-m, 7.2 ft-lb) Tighten the bolts (s) and (t) in alphabetical sequence. NOTE: Use a new seal washer. Install and tighten the seal washer to the bolt. Tightening torque: 9.75 N.m (1.0 kgf-m, 7.2 ft-lb)
3. Apply a coat of engine oil to camshaft oil seal periphery and oil seal lips and install the oil seal (A) on camshaft using ST1 and ST2. NOTE: Use a new oil seal. ST1 499597000 OIL SEAL GUIDE ST2 499587500 OIL SEAL INSTALLER
4. Apply a coat of engine oil to plug periphery and Install the plug (A) using ST. ST 499587700 CAMSHAFT OIL SEAL INSTALLER
5. Install the camshaft position sensor support. (LH side only) Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
6. Similarly, install the parts on right-hand side.
7. Install the tensioner bracket. Tightening torque: 24.5 N.m (2.5 kgf-m, 18.1 ft-lb)
8. Install the timing belt cover No. 2 RH. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
9. Install the timing belt cover No. 2 (LH). Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
10. Install the cam sprocket. Refer to «INSTALLATION»(ref-325301-S15499740302009071800000) , Cam Sprocket .
11. Install the timing belt. Refer to «INSTALLATION»(ref-325301-S23320513242009071800000) , Timing Belt .
12. Adjust the valve clearance. Refer to «ADJUSTMENT»(ref-325301-S24451996572009071800000) , Valve Clearance .
13. Install the rocker cover. Install the rocker cover gasket to the rocker cover. NOTE: Use a new rocker cover gasket. Temporarily tighten the bolts in alphabetical sequence as shown in figure, then tighten the bolt in 2 steps. Tightening torque: 1st 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 2nd (only (a) and (b) are tightened) 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) RH side LH side
14. Connect the PCV hose. NOTE: For the PCV hose clamp, use a new clamp. Sandwich the protruding part of the clamp with the ST and lock the clamp. ST 18353AA000 CLAMP PLIERS
15. Install the high tension cord.
16. Install the timing belt cover. Refer to «INSTALLATION»(ref-325301-S08843078112009071800000) , Timing Belt Cover .
17. Install the crank pulley. Refer to «INSTALLATION»(ref-325301-S27405060002009071800000) , Crank Pulley .
18. Install the V-belts. Refer to «INSTALLATION»(ref-325301-S10873526442009071800000) , V-belt .

Scheme 166

Scheme 167

1. Measure the bend, and repair or replace if necessary. Service limit: 0.025 mm (0.00098 in)
2. Check the journal for damage and wear. Replace if faulty.
3. Measure the outer diameter of camshaft journal and inner diameter of cylinder head journal, and check the difference (oil clearance) between the two values. If the oil clearance is not within the standard, replace the camshaft or cylinder head as necessary. OIL CLEARANCE SPECIFICATION Unit: mm (in) Oil clearance Standard 0.055 - 0.090 (0.0022 - 0.0035) Camshaft journal O.D. 31.928 - 31.945 (1.2570 - 1.2577) Journal hole I.D. 32.000 - 32.018 (1.2598 - 1.2605)
4. Check the cam face condition, and remove the minor faults by grinding with oil stone. Measure the cam height H. If it is not within the standard or offset wear occurs, replace it. Cam height H: CAM HEIGHT SPECIFICATION Unit: mm (in) Intake Constant Standard 40.075 - 40.175 (1.5778 - 1.5817) Low speed Standard 35.496 - 35.596 (1.3975 - 1.4014) High speed Standard 40.315 - 40.415 (1.5872 - 1.5911) Exhaust Standard 39.289 - 39.389 (1.5468 - 1.5507) Cam base circle diameter A: Intake 34.00 mm (1.3386 in) Exhaust 34.00 mm (1.3386 in) Base circle step of adjacent intake cams (low speed and high speed): 0.03 mm (0.001 in) or less
5. 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: 0.030 - 0.090 mm (0.0012 - 0.0035 in)

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

Scheme 168

1. Remove the V-belts. Refer to «REMOVAL»(ref-325301-S15291069492009071800000) , V-belt .
2. Remove the intake manifold. Refer to «REMOVAL»(ref-325305-S14612553792009071800000) , Intake Manifold .
3. Remove the crank pulley. Refer to «REMOVAL»(ref-325301-S42579091412009071800000) , Crank Pulley .
4. Remove the timing belt cover. Refer to «REMOVAL»(ref-325301-S32499370542009071800000) , Timing Belt Cover .
5. Remove the timing belt. Refer to «REMOVAL»(ref-325301-S23657586352009071800000) , Timing Belt .
6. Remove the cam sprocket. Refer to «REMOVAL»(ref-325301-S13353465022009071800000) , Cam Sprocket .
7. Remove the bolt which installs the A/C compressor bracket on cylinder head.
8. Remove the valve rocker assembly. Refer to «REMOVAL»(ref-325301-S06727693812009071800000) , Valve Rocker Assembly .
9. Remove the camshaft. Refer to «REMOVAL»(ref-325301-S19183750952009071800000) , Camshaft .
10. Remove the oil level gauge guide. (LH side)
11. Remove the cylinder head bolts in alphabetical sequence as shown in the figure. NOTE: Leave bolts (a) and (c) 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 (c) 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 169

1. Install the cylinder head and gaskets on cylinder block. CAUTION: Be careful not to scratch the mating surface of cylinder block and cylinder head. 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. 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 42 N.m (4.3 kgf-m, 31.0 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) Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
4. Install the camshaft. Refer to «INSTALLATION»(ref-325301-S00112240392009071800000) , Camshaft .
5. Install the valve rocker assembly. Refer to «INSTALLATION»(ref-325301-S21201125512009071800000) , Valve Rocker Assembly .
6. Install the A/C compressor bracket on cylinder head. Tightening torque: 36 N.m (3.7 kgf-m, 26.6 ft-lb)
7. Install the cam sprocket. Refer to «INSTALLATION»(ref-325301-S15499740302009071800000) , Cam Sprocket .
8. Install the timing belt. Refer to «INSTALLATION»(ref-325301-S23320513242009071800000) , Timing Belt .
9. Adjust the valve clearance. Refer to «ADJUSTMENT»(ref-325301-S24451996572009071800000) , Valve Clearance .
10. Install the rocker cover. Install the rocker cover gasket to the rocker cover. NOTE: Use a new rocker cover gasket. Temporarily tighten the bolts in alphabetical sequence as shown in figure, then tighten the bolt in 2 steps. Tightening torque: 1st 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 2nd (only (a) and (b) are tightened) 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) RH side LH side
11. Install the timing belt cover. Refer to «INSTALLATION»(ref-325301-S08843078112009071800000) , Timing Belt Cover .
12. Install the crank pulley. Refer to «INSTALLATION»(ref-325301-S27405060002009071800000) , Crank Pulley .
13. Install the intake manifold. Refer to «INSTALLATION»(ref-325305-S08496221032009071800000) , Intake Manifold .
14. Install the V-belts. Refer to «INSTALLATION»(ref-325301-S10873526442009071800000) , V-belt .

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

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1. Remove the V-belts. Refer to «REMOVAL»(ref-325301-S15291069492009071800000) , V-belt .
2. Remove the intake manifold. Refer to «REMOVAL»(ref-325305-S14612553792009071800000) , Intake Manifold .
3. Remove the crank pulley. Refer to «REMOVAL»(ref-325301-S42579091412009071800000) , Crank Pulley .
4. Remove the timing belt cover. Refer to «REMOVAL»(ref-325301-S32499370542009071800000) , Timing Belt Cover .
5. Remove the timing belt. Refer to «REMOVAL»(ref-325301-S23657586352009071800000) , Timing Belt .
6. Remove the cam sprocket. Refer to «REMOVAL»(ref-325301-S13353465022009071800000) , Cam Sprocket .
7. Remove the crank sprocket. Refer to «REMOVAL»(ref-325301-S13144200832009071800000) , Crank Sprocket .
8. Remove the generator and A/C compressor with their brackets.
9. Remove the cylinder head. Refer to «REMOVAL»(ref-325301-S36727711962009071800000) , Cylinder Head .
10. Remove the clutch disc and cover. (MT model) Refer to «REMOVAL»(ref-325307-S04333455262009071800000) , Clutch Disc and Cover .
11. Remove the flywheel. (MT model) Refer to «REMOVAL»(ref-325307-S42514974482009071800000) , Flywheel .
12. Remove the drive plate. (AT model) Using the ST, lock the crankshaft. ST 498497100 CRANKSHAFT STOPPER
13. Remove the oil separator cover.
14. Remove the water by-pass pipe for heater.
15. Remove the water pump. Refer to «REMOVAL»(ref-325303-S12200183092009071800000) , 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 oil filter. Refer to «REMOVAL»(ref-325324-S19660321582009071800000) , Engine Oil Filter .
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 draw out 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 the 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. Remove 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 179

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

Scheme 202

Scheme 203

Scheme 204

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 the LH side (A - D) in alphabetical order. Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb)
6. Tighten the 10 mm cylinder block connecting bolts on the RH side (E - J) in alphabetical order. Tightening torque: 10 N.m (1.0 kgf-m, 7.4 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 LH side (A - H) in alphabetical sequence. 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) on the 180° opposite direction of (C) in the figure.
18. Set the lower rail gap at position (G), located 120° clockwise from (C) in the figure. 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 the 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 piston pin hole with 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. 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.
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 baffle plate. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
24. Install the oil strainer. NOTE: Use new O-rings. Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb)
25. Tighten the oil strainer stay together with the baffle plate. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
26. Apply liquid gasket to the mating surfaces of the 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)
27. Apply liquid gasket to the mating surfaces of the 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 a new separator cover. Liquid gasket: Mating surface THREE BOND 1217G (Part No. K0877Y0100) or equivalent Bolt thread area (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)
28. Install the flywheel. (MT model) Refer to «INSTALLATION»(ref-325307-S22159988392009071800000) , Flywheel .
29. Install the clutch disc and cover. (MT model) Refer to «INSTALLATION»(ref-325307-S26235060392009071800000) , Clutch Disc and Cover .
30. Install the drive plate. (AT model) To lock the crankshaft, use the ST. ST 498497100 CRANKSHAFT STOPPER Tightening torque: 72 N.m (7.3 kgf-m, 53.1 ft-lb)
31. 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 assemble O-rings. 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: T: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
32. Install the water pump and gasket. NOTE: When installing the water pump, tighten bolts in two stages in alphabetical order 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)
33. Install the water by-pass pipe for heater. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
34. Install the oil filter. Refer to «INSTALLATION»(ref-325324-S26426810192009071800000) , Engine Oil Filter .
35. Install the cylinder head. Refer to «INSTALLATION»(ref-325301-S31714591232009071800000) , Cylinder Head .
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-325301-S24480142752009071800000) , Crank Sprocket .
38. Install the cam sprocket. Refer to «INSTALLATION»(ref-325301-S15499740302009071800000) , Cam Sprocket .
39. Install the timing belt. Refer to «INSTALLATION»(ref-325301-S23320513242009071800000) , Timing Belt .
40. Adjust the valve clearance. Refer to «ADJUSTMENT»(ref-325301-S24451996572009071800000) , Valve Clearance .
41. Install the rocker cover. Install the rocker cover gasket to the rocker cover. NOTE: Use a new rocker cover gasket. Temporarily tighten the bolts in alphabetical sequence as shown in figure, then tighten the bolt in 2 steps. Tightening torque: 1st 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 2nd (only (a) and (b) are tightened) 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) RH side LH side
42. Install the timing belt cover. Refer to «INSTALLATION»(ref-325301-S08843078112009071800000) , Timing Belt Cover .
43. Install the crank pulley. Refer to «INSTALLATION»(ref-325301-S27405060002009071800000) , Crank Pulley .
44. Install the intake manifold. Refer to «INSTALLATION»(ref-325305-S08496221032009071800000) , Intake Manifold .
45. Install the V-belts. Refer to «INSTALLATION»(ref-325301-S10873526442009071800000) , V-belt .

Scheme 205

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 206

1. Apply oil to the surface of the connecting rod bearings, and install the connecting rod bearings on connecting rods and connecting rod caps.
2. Position each connecting rod with the side with a side mark facing forward, and install it.
3. Attach the connecting rod cap, and tighten with connecting rod nut. 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 nuts, apply oil on the threads. Tightening torque: 45 N.m (4.6 kgf-m, 33.2 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.