Engine Mechanical (h4dotc) Subaru Impreza WRX GH

SPECIFICATION

GENERAL SPECIFICATION

Note. OS: Oversize US: Undersize

GENERAL SPECIFICATION

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

SPECIAL TOOL

SPECIAL TOOL CHART ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498267600 CYLINDER HEAD TABLE Used for replacing valve guides. Used for removing and installing valve spring. 498277200 STOPPER SET Used for installing automatic transmission assembly to engine. 498457000 ENGINE STAND ADAPTER RH Used together with the ENGINE STAND (499817100). 498457100 ENGINE STAND ADAPTER LH Used together with the ENGINE STAND (499817100). 498497100 CRANKSHAFT STOPPER Used for removing and installing flywheel and drive plate. 498747300 PISTON GUIDE Used for installing the cup to the wheel cylinder piston. (2.5 L model) 498857100 VALVE OIL SEAL GUIDE Used for press-fitting of intake and exhaust valve guide oil seals. 499017100 PISTON PIN GUIDE Used for installing piston pin, piston and connecting rod. 499037100 CONNECTING ROD BUSHING REMOVER AND INSTALLER Used for removing and installing connecting rod bushing. 499097700 PISTON PIN REMOVER ASSY Used for removing piston pin. 499207400 CAM SPROCKET WRENCH Used for removing and installing exhaust cam sprocket. 499587100 OIL SEAL INSTALLER Used for installing oil pump oil seal. 499587200 CRANKSHAFT OIL SEAL INSTALLER Used for installing crankshaft oil seal. Used together with the CRANKSHAFT OIL SEAL GUIDE (499597100). 499587600 OIL SEAL INSTALLER Used for installing camshaft oil seal for DOHC engine. 499597100 CRANKSHAFT OIL SEAL GUIDE Used for installing crankshaft oil seal. Used together with the CRANKSHAFT OIL SEAL INSTALLER (499587200). 499597200 OIL SEAL GUIDE Used for installing camshaft oil seal for DOHC engine. Used together with the OIL SEAL INSTALLER (499587600). 499718000 VALVE SPRING REMOVER Used for removing and installing valve spring. 499767200 VALVE GUIDE REMOVER Used for removing valve guides. 499767400 VALVE GUIDE REAMER Used for reaming valve guides. 499817100 ENGINE STAND Stand used for engine disassembly and assembly. Used together with the ENGINE STAND ADAPTER RH (498457000) & LH (498457100). 499977100 CRANK PULLEY WRENCH Used to stop rotation of the crank pulley when loosening or tightening crank pulley bolts. (MT model) 499977400 CRANK PULLEY WRENCH Used to stop rotation of the crank pulley when loosening or tightening crank pulley bolts. (AT model) 499977500 CAM SPROCKET WRENCH Used for removing and installing intake cam sprocket. 499987500 CRANKSHAFT SOCKET Used for rotating crankshaft. 18251AA020 VALVE GUIDE ADJUSTER Used for installing intake and exhaust valve guides. 18371AA000 CONNECTOR REMOVER Used for disconnecting the quick connector on the fuel return hose of the engine compartment. 42099AE000 QUICK CONNECTOR RELEASE Used for disconnecting quick connector of the engine compartment. 1B021XU0 SUBARU SELECT MONITOR III KIT Used for troubleshooting the electrical system

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GENERAL TOOL

GENERAL TOOL CHART

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

INSPECTION

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1. After warming-up the engine, turn the ignition switch to OFF.
2. Make sure that the battery is fully charged.
3. Release the fuel pressure. RELEASING OF FUEL PRESSURE , PROCEDURE, Fuel . >
4. Remove all the spark plugs. REMOVAL , Spark Plug . >
5. Fully open the throttle valve.
6. Check the starter motor for satisfactory performance and operation.
7. Hold the compression gauge tightly against the spark plug hole. NOTE: When using a screw-in type compression gauge, the screw should be less than 18 mm (0.71 in) long.
8. Crank the engine by the starter motor, and read the maximum value on the gauge when the needle of gauge is steady.
9. Perform at least two measurements per cylinder, and make sure that the values are correct. Compression (fully open throttle): Standard 981 - 1,177 kPa (10 - 12 kgf/cm 2 , 142 - 171 psi) Difference between cylinders 49 kPa (0.5 kgf/cm 2 , 7 psi), or less
10. After inspection, install the related parts in the reverse order of removal.

1. Before checking the idle speed, check the following item: Check the air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and hoses are connected properly. Check the malfunction indicator light does not illuminate.
2. Warm-up the engine.
3. Read the engine idle speed using Subaru Select Monitor. READ CURRENT DATA FOR ENGINE (NORMAL MODE) , OPERATION, Subaru Select Monitor . >
4. Check the idle speed when no-loaded. (Headlight, heater fan, rear defroster, radiator fan, A/C and etc. are OFF) Idle speed [No load and gears in neutral, "P" or "N" range]: 750 ± 100 rpm
5. Check the idle speed when loaded. (Turn the A/C switch to "ON" and operate the compressor for at least one minute before measurement.)

Idle speed [A/C ON and gears in neutral, "P" or "N" range]

800 ± 100 rpm (MT model)

825 ± 100 rpm (AT model)

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

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. READ CURRENT DATA FOR ENGINE (NORMAL MODE) , OPERATION, Subaru Select Monitor . >

Ignition timing [BTDC/rpm]

12° ± 10°/750 (MT Model)

17° ± 10°/750 (AT Model)

If the timing is not correct, check the ignition control system. Refer to "Engine Control System". 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 air intake duct.
5. Disconnect the connectors of the mass air flow and intake air temperature sensor.
6. Remove the air cleaner case and element.
7. Connect the timing light to the power wire of #1 ignition coil.
8. Attach the air cleaner case, element and connector of mass air flow and intake air temperature sensor.
9. 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]

12° ± 10°/750 (MT Model)

17° ± 10°/750 (AT Model)

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

1. Warm-up the engine.
2. Disconnect the brake booster vacuum hose from the intake manifold, and then install the vacuum gauge.
3. Keep the engine at idle speed and read the vacuum gauge indication.

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

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Vacuum pressure (at idling, A/C OFF)

Less than -70.6 kPa

(-530 mmHg, -20.85 inHg) (MT model)

Less than -68.0 kPa

(-510 mmHg, -20.08 inHg) (AT model)

VACUUM PRESSURE SPECIFICATION

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1. Disconnect the ground cable from the battery.
2. Remove the oil pressure switch. REMOVAL , Oil Pressure Switch . >
3. Connect the oil pressure gauge hose to cylinder block.
4. Connect the battery ground cable to the battery.
5. Start the engine, and measure the oil pressure. Oil pressure: Standard 98 kPa (1.0 kgf/cm 2 , 14 psi) or more (at 600 rpm) 294 kPa (3.0 kgf/cm 2 , 43 psi) or more (at 5,000 rpm) If the oil pressure is out of specification, check oil pump, oil filter and lubrication line. INSPECTION , Engine Lubrication System Trouble in General . > If the oil pressure warning light is ON and oil pressure is within specification, check the oil pressure switch. INSPECTION , Engine Lubrication System Trouble in General . > NOTE: Standard value is based on an engine oil temperature of 80°C (176°F).
6. After measuring the oil pressure, install the oil pressure switch. INSTALLATION , Oil Pressure Switch . >

Note. If the fuel pressure is out of specification, check or replace the pressure regulator and pressure regulator vacuum hose.

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1. Release the fuel pressure. RELEASING OF FUEL PRESSURE , PROCEDURE, Fuel . >
2. Open the fuel filler flap lid, and remove the fuel filler cap.
3. Disconnect the fuel delivery hose from fuel damper valve, and connect fuel pressure gauge.
4. Install the fuse of fuel pump to the main fuse box.
5. Start the engine.
6. Measure the fuel pressure while disconnecting pressure regulator vacuum hose from intake manifold. NOTE: The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kgf/cm 2 , 1 to 3 psi) higher than standard values during high-altitude operations. Fuel pressure: Standard 284 - 314 kPa (2.9 - 3.2 kgf/cm 2 , 41 - 46 psi)
7. After connecting the pressure regulator vacuum hose, measure the fuel pressure.

Note. The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kgf/cm 2 , 1 to 3 psi) higher than standard values during high-altitude operations.

Fuel pressure

Standard

230 - 260 kPa

(2.35 - 2.65 kgf/cm 2 , 33 - 38 psi)

Note. Inspection and adjustment of valve clearance should be performed while engine is cold.

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1. Set the vehicle on a lift.
2. Disconnect the ground cable from the battery.
3. Remove the air intake duct. REMOVAL , Air Intake Duct . >
4. Remove the bolt which secures timing belt cover RH.
5. Lift up the vehicle.
6. Remove the under cover.
7. Loosen the remaining bolts which secure timing belt cover RH, then remove the timing belt cover.
8. Lower the vehicle.
9. When inspecting #1 and #3 cylinders Remove the air cleaner case. REMOVAL , Air Cleaner Case . > Disconnect the connector of ignition coil. Remove the ignition coil. Place a suitable container under the vehicle. Disconnect the PCV hose from the rocker cover RH. Remove the bolts, then remove the rocker cover RH.
10. When inspecting #2 and #4 cylinders Disconnect the battery cable, and then remove the battery and battery carrier. Remove the secondary air pump. REMOVAL , Secondary Air Pump . > Disconnect the connector of ignition coil. Remove the ignition coil. Place a suitable container under the vehicle. Disconnect the PCV hose from the rocker cover LH. Remove the bolts, then remove the rocker cover LH.
11. Turn the crank pulley clockwise until the round mark and arrow mark on the camshaft sprocket are set to position shown in the figure. NOTE: Turn the crank pulley using a socket wrench.
12. Measure the #1 cylinder intake valve and #3 cylinder exhaust valve clearance by using thickness gauge (A). NOTE: Insert a thickness gauge in a direction as horizontal as possible with respect to the valve lifter. Lift up the vehicle and measure the exhaust valve clearances. If the measured value is not within specification, take notes of the value in order to adjust the valve clearance later on. Valve clearance (inspection value): Intake 0.20 +0.04 -0.06 mm (0.0079 +0.00016 -0.0024 in) Exhaust 0.35 ± 0.05 mm (0.0138 ± 0.0020 in)
13. If necessary, adjust the valve clearance. ADJUSTMENT, Valve Clearance. >
14. Further turn the crank pulley clockwise and then measure the valve clearances again. Set the round mark and arrow mark on cam sprocket to the position shown in the figure, and measure the #2 cylinder exhaust valve and #3 cylinder intake valve clearances. Set the round mark and arrow mark on cam sprocket to the position shown in the figure, and measure the #2 cylinder intake valve and #4 cylinder exhaust valve clearances. Set the round mark and arrow mark on cam sprocket to the position shown in the figure, and measure the #1 cylinder exhaust valve and #4 cylinder intake valve clearances.
15. After inspection, install the related parts in the reverse order of removal.

ADJUSTMENT

Note. Adjustment of valve clearance should be performed while engine is cold.

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1. Measure all the valve clearances. INSPECTION, Valve Clearance. > NOTE: Record each valve clearance after measurement.
2. Remove the camshaft. REMOVAL, Camshaft. >
3. Remove the valve lifter.
4. Measure the thickness of valve lifter using micrometer.
5. Select and install a valve lifter of suitable thickness from the following table, based on the measured valve clearance and valve lifter thickness. VALVE LIFTER THICKNESS SPECIFICATION Unit: (mm) Intake valve: S = (V + T) - 0.19 Exhaust valve: S = (V + T) - 0.35 S: Valve lifter thickness required V: Measured valve clearance T: Valve lifter thickness to be used VALVE LIFTER THICKNESS SPECIFICATION Part No. Thickness mm (in) 13228 AB102 4.68 (0.1843) 13228 AB112 4.69 (0.1846) 13228 AB122 4.70 (0.1850) 13228 AB132 4.71 (0.1854) 13228 AB142 4.72 (0.1858) 13228 AB152 4.73 (0.1862) 13228 AB162 4.74 (0.1866) 13228 AB172 4.75 (0.1870) 13228 AB182 4.76 (0.1874) 13228 AB192 4.77 (0.1878) 13228 AB202 4.78 (0.1882) 13228 AB212 4.79 (0.1886) 13228 AB222 4.80 (0.1890) 13228 AB232 4.81 (0.1894) 13228 AB242 4.82 (0.1898) 13228 AB252 4.83 (0.1902) 13228 AB262 4.84 (0.1906) 13228 AB272 4.85 (0.1909) 13228 AB282 4.86 (0.1913) 13228 AB292 4.87 (0.1917) 13228 AB302 4.88 (0.1921) 13228 AB312 4.89 (0.1925) 13228 AB322 4.90 (0.1929) 13228 AB332 4.91 (0.1933) 13228 AB342 4.92 (0.1937) 13228 AB352 4.93 (0.1941) 13228 AB362 4.94 (0.1945) 13228 AB372 4.95 (0.1949) 13228 AB382 4.96 (0.1953) 13228 AB392 4.97 (0.1957) 13228 AB402 4.98 (0.1961) 13228 AB412 4.99 (0.1965) 13228 AB422 5.00 (0.1969) 13228 AB432 5.01 (0.1972) 13228 AB442 5.02 (0.1976) 13228 AB452 5.03 (0.1980) 13228 AB462 5.04 (0.1984) 13228 AB472 5.05 (0.1988) 13228 AB482 5.06 (0.1992) 13228 AB492 5.07 (0.1996) 13228 AB502 5.08 (0.2000) 13228 AB512 5.09 (0.2004) 13228 AB522 5.10 (0.2008) 13228 AB532 5.11 (0.2012) 13228 AB542 5.12 (0.2016) 13228 AB552 5.13 (0.2020) 13228 AB562 5.14 (0.2024) 13228 AB572 5.15 (0.2028) 13228 AB582 5.16 (0.2031) 13228 AB592 5.17 (0.2035) 13228 AB602 5.18 (0.2039) 13228 AB612 5.19 (0.2043) 13228 AB622 5.20 (0.2047) 13228 AB632 5.21 (0.2051) 13228 AB642 5.22 (0.2055) 13228 AB652 5.23 (0.2059) 13228 AB662 5.24 (0.2063) 13228 AB672 5.25 (0.2067) 13228 AB682 5.26 (0.2071) 13228 AB692 5.27 (0.2075) 13228 AB702 4.38 (0.1724) 13228 AB712 4.40 (0.1732) 13228 AB722 4.42 (0.1740) 13228 AB732 4.44 (0.1748) 13228 AB742 4.46 (0.1756) 13228 AB752 4.48 (0.1764) 13228 AB762 4.50 (0.1771) 13228 AB772 4.52 (0.1780) 13228 AB782 4.54 (0.1787) 13228 AB792 4.56 (0.1795) 13228 AB802 4.58 (0.1803) 13228 AB812 4.60 (0.1811) 13228 AB822 4.62 (0.1819) 13228 AB832 4.64 (0.1827) 13228 AB842 4.66 (0.1835) 13228 AB852 5.29 (0.2083) 13228 AB862 5.31 (0.2091) 13228 AB872 5.33 (0.2098) 13228 AB882 5.35 (0.2106) 13228 AB892 5.37 (0.2114) 13228 AB902 5.39 (0.2122) 13228 AB912 5.41 (0.2123) 13228 AB922 5.43 (0.2138) 13228 AB932 5.45 (0.2146) 13228 AB942 5.47 (0.2154) 13228 AB952 5.49 (0.2161) 13228 AB962 5.51 (0.2169) 13228 AB972 5.53 (0.2177) 13228 AB982 5.55 (0.2185) 13228 AB992 5.57 (0.2193) 13228 AC002 5.59 (0.2201) 13228 AC012 5.61 (0.2209) 13228 AC022 5.63 (0.2217) 13228 AC032 5.65 (0.2224)
6. Install the camshaft. INSTALLATION, Camshaft. >
7. Install the cam sprocket. INSTALLATION, Cam Sprocket. >
8. Install the timing belt. TIMING BELT, INSTALLATION, Timing Belt. >
9. Measure all valves for valve clearance again at this time. If the valve clearance is not within the adjustment value, repeat the procedure over again from the first step. Valve clearance (adjustment value): Intake 0.20 +0.01 -0.03 mm (0.0079 +0.0004 -0.0012 in) Exhaust 0.35 ± 0.02 mm (0.0138 ± 0.0008 in)
10. After measuring, install the related parts in the reverse order of removal.

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1. Set the vehicle on a lift.
2. Change the bolt mounting position from (A) to (B), and completely open the front hood. Tightening torque: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)
3. Remove the V-belt covers.
4. Collect the refrigerant from the A/C system. REFRIGERANT RECOVERY PROCEDURE . >
5. Release the fuel pressure. RELEASING OF FUEL PRESSURE , PROCEDURE, Fuel . >
6. Disconnect the battery cable, and remove the battery from the vehicle.
7. Open the fuel filler flap lid, and remove the fuel filler cap.
8. Remove the air intake duct and air cleaner case. REMOVAL , Air Intake Duct . > REMOVAL , Air Cleaner Case . >
9. Remove the intercooler. REMOVAL , Intercooler . >
10. Remove the radiator from the vehicle. REMOVAL , Radiator . >
11. Remove the coolant filler tank. REMOVAL , Coolant Filler Tank . >
12. Disconnect the A/C pressure hoses from A/C compressor. REMOVAL , Hose and Tube . >
13. Disconnect the following connectors and cables. Engine harness connectors Engine ground terminal Generator connector and terminal A/C compressor connector
14. Disconnect the following hoses. Brake booster vacuum hose Heater inlet and outlet hoses
15. Remove the power steering pump. Remove the front side belts. FRONT SIDE BELT, REMOVAL, V-belt. > Disconnect the power steering pump switch connector. Remove the power steering pump from the engine. REMOVAL , Oil Pump . > Place the power steering pump on the right side wheel apron.
16. Lift up the vehicle.
17. Remove the front and center exhaust pipes. REMOVAL , Front Exhaust Pipe . > REMOVAL , Center Exhaust Pipe . >
18. Disconnect the ground cable on the engine side.
19. Remove the bolts and nuts which hold the lower side of transmission to the engine. AT model MT model
20. Remove the nuts which hold the engine mount to the front cross member.
21. Separate the torque converter clutch from drive plate. (AT model) Lower the vehicle. Remove the service hole plug. Remove the bolts which hold torque converter clutch to drive plate. Remove other bolts while rotating the crankshaft using socket wrench.
22. Remove the pitching stopper.
23. Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose. ST 42099AE000 QUICK CONNECTOR RELEASE CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth.
24. Disconnect the fuel return hose using the ST. ST 18371AA000 CONNECTOR REMOVER CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth. Attach the ST to the fuel return pipe as shown in the figure. Insert the front side of ST into the quick connector. Insert the back side of ST into the quick connector and push ST in the direction of arrow mark to disconnect the fuel return hose.
25. Remove the clip and disconnect the evaporation hose from the fuel pipe.
26. Support the engine with a lifting device and wire ropes.
27. Support the transmission with a garage jack. CAUTION: Doing this is very important to prevent the transmission from lowering due to its own weight.
28. Separation of engine and transmission. CAUTION: Before removing the engine away from transmission, check to be sure no work has been overlooked. Remove the starter. REMOVAL , Starter . > Set the ST to torque converter clutch case. (AT model) ST 498277200 STOPPER SET Remove the bolts which hold the upper side of the transmission to the engine. AT model MT model
29. Remove the engine from vehicle. Slightly raise the engine. Raise the transmission with garage jack. Move the engine horizontally until main shaft is withdrawn from clutch cover. Slowly move the engine away from engine compartment. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
30. Remove the engine mount from the engine.

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1. Install the engine mount onto the engine. Tightening torque: 35 N.m (3.6 kgf-m, 25.8 ft-lb)
2. Apply a small amount of grease to splines of main shaft. (MT model)
3. Position the engine in engine compartment and align it with transmission. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
4. Tighten the bolts which hold upper side of transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb) AT model MT model
5. Remove the lifting device and wire ropes.
6. Remove the garage jack.
7. Install the pitching stopper. Tightening torque: T1: 50 N.m (5.1 kgf-m, 36.9 ft-lb) T2: 58 N.m (5.9 kgf-m, 42.8 ft-lb)
8. Remove the ST from the torque converter clutch case. (AT model) NOTE: Be careful not to drop the ST into the torque converter clutch case when removing the ST. ST 498277200 STOPPER SET
9. Install the starter. INSTALLATION , Starter . >
10. Install the torque converter clutch to drive plate. (AT model) Tighten the bolts which hold torque converter clutch to drive plate. Tighten other bolts while rotating the crankshaft using socket wrench. NOTE: Be careful not to drop bolts into the torque converter clutch housing. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb) Fit the plug to service hole.
11. Install the power steering pump. Install the power steering pump. Tightening torque: Refer to "COMPONENT" of "Power Steering" for the tightening torque. COMPONENT , General Description . > Connect the power steering pump switch connector. Install and adjust the front side belt. FRONT SIDE BELT, INSTALLATION, V-belt. >
12. Lift up the vehicle.
13. Tighten the bolts and nuts which hold lower side of the transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb) AT model MT model
14. Tighten the nuts which hold the engine mount to the cross member. NOTE: Make sure that the engine mount nuts (A) and locator (B) are securely installed. Tightening torque: 85 N.m (8.7 kgf-m, 62.7 ft-lb)
15. Connect the ground cable. Tightening torque: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)
16. Install the front and center exhaust pipe. INSTALLATION , Center Exhaust Pipe . > INSTALLATION , Front Exhaust Pipe . >
17. Lower the vehicle.
18. Connect the following hoses. Fuel delivery hose, fuel return hose and evaporation hose Heater inlet and outlet hoses Brake booster vacuum hose
19. Connect the following connectors and terminals. Engine ground terminal Tightening torque: 14 N.m (1.4 kgf-m, 10.3 ft-lb) Engine harness connectors Generator connector and terminal Tightening torque: 15 N.m (1.5 kgf-m, 11.1 ft-lb) A/C compressor connector
20. Install the intercooler. INSTALLATION , Intercooler . >
21. Install the A/C pressure hoses. INSTALLATION , Hose and Tube . >
22. Install the radiator. INSTALLATION , Radiator . >
23. Install the coolant filler tank. INSTALLATION , Coolant Filler Tank . >
24. Install the air cleaner case and air intake duct. INSTALLATION , Air Cleaner Case . > INSTALLATION , Air Intake Duct . >
25. Install the battery to the vehicle, and connect the battery cables.
26. Fill engine coolant. FILLING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant . >
27. Charge the A/C system with refrigerant. PROCEDURE , Refrigerant Charging Procedure . >
28. Check the ATF level and replenish it if necessary. (AT model) INSPECTION , Automatic Transmission Fluid . >
29. Install the V-belt cover. Tightening torque: 13 N.m (1.3 kgf-m, 9.6 ft-lb)
30. Change the bolt mounting position from (B) to (A), and close the front hood. Tightening torque: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)
31. Lower the vehicle from the lift.

1. Check that pipes, hoses, connectors and clamps are installed firmly.
2. Check that the engine coolant is at specified level.
3. Check that the ATF is at specified level. (AT model)
4. Start the engine and check for exhaust gas, engine coolant, leaks of fuel, etc. Also check for noise and vibrations.

REMOVAL

1. Remove the engine unit. REMOVAL, 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)

Make sure that no crack or other damages do not exist.

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1. After removing the engine from body, secure it to ST in the following procedure. ST1 498457000 ENGINE STAND ADAPTER RH ST2 498457100 ENGINE STAND ADAPTER LH ST3 499817100 ENGINE STAND
2. In this article the procedures described under each index are all connected and stated in order. The procedure for overhauling of the engine will be completed when you go through all steps in the process.

Therefore, in this article, to conduct the particular procedure within the flow of a section, you need to go back and conduct the procedure described previously in order to do that particular procedure.

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

FRONT SIDE BELT

1. Remove the V-belt covers.
2. Remove the air intake duct. REMOVAL , Air Intake Duct . >
3. Loosen the bolt (A).
4. Loosen the slider bolt (B).
5. Remove the front side belt (C).

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REAR SIDE BELT

1. Remove the front side belts. FRONT SIDE BELT , REMOVAL, V-belt . >
2. Cut the rear side belt with a wire cutter, etc., and discard.

Scheme 363

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. INSPECTION, 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 air intake duct. INSTALLATION , Air Intake Duct . >
6. Install the V-belt cover.

Tightening torque

13 N.m (1.3 kgf-m, 9.6 ft-lb)

Scheme 364

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Scheme 375

Scheme 376

Scheme 377

Scheme 378

Scheme 379

Scheme 380

Scheme 381

Scheme 382

Scheme 383

Scheme 384

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.
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. 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. FRONT SIDE BELT , 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)

Scheme 385

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)

Scheme 386

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.

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

Scheme 387

1. Remove the V-belts. REMOVAL, 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.

AT MODEL

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-belts. INSTALLATION, V-belt. >

MT MODEL

1. Install the crank pulley.
2. Use the ST to lock the crank pulley, and attach the crank pulley bolts. ST 499977100 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: 180 N.m (18.4 kgf-m, 132.8 ft-lb)
3. Check that the tightening angle of the crank pulley bolt is 65° or more. Perform the following procedure when less than 65°. CAUTION: If the tightening angle of crank pulley bolt is less than 65°, 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 65° to 75°. 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-belts. INSTALLATION, V-belt. >

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

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

1. Remove the secondary air pump. REMOVAL , Secondary Air Pump . >
2. Remove the V-belts. REMOVAL, V-belt. >
3. Remove the crank pulley. REMOVAL, 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 388

Scheme 389

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. INSTALLATION, Crank Pulley. >
5. Install the V-belts. INSTALLATION, V-belt. >
6. Install the secondary air pump. INSTALLATION , Secondary Air Pump . >

Check the timing belt cover for damage.

Note. Perform the work with the engine installed to body when replacing a single part. For operation procedures, refer to TIMING BELT . >

Scheme 390

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Scheme 397

Scheme 398

1. Remove the V-belts. REMOVAL, V-belt. >
2. Remove the crank pulley. REMOVAL, Crank Pulley. >
3. Remove the timing belt cover. REMOVAL, Timing Belt Cover. >
4. Remove the timing belt guide. (MT model)
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. 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
6. Remove the belt idler (A).
7. Remove the timing belt. CAUTION: After the timing belt has been removed, never rotate the intake and exhaust sprocket. If the cam sprocket is rotated, the intake and exhaust valve heads strike together and valve stems are bent.

Scheme 399

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

Scheme 400

Scheme 401

Scheme 402

Scheme 403

1. Prepare for installation of automatic belt tension adjuster assembly. CAUTION: Always use a vertical type pressing tool to move the adjuster rod down. Do not use a lateral type vise. Push the adjuster rod vertically. Press-in the push adjuster rod gradually taking 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 404

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Scheme 419

1. Prepare for installation of the automatic belt tension adjuster assembly. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER, 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 do not push the intake and exhaust valves down. (Under this condition, all valves remain unlifted.) When the camshafts are rotated to install the timing belts, #2 intake and #4 exhaust cam of 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 guide. (MT model) Temporarily tighten the bolts mounting the timing belt guide. NOTE: Before attaching the bolts, clean the bolt holes of the timing belt cover. Apply liquid gasket to the threaded portion of cam sprocket, (when reusing bolts) Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent Check and adjust the clearance between timing belt and timing belt guide using a 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) Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
12. Install the timing belt cover. INSTALLATION, Timing Belt Cover. >
13. Install the crank pulley. INSTALLATION, Crank Pulley. >
14. Install the V-belts. INSTALLATION, V-belt. >

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

Scheme 420

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)

Scheme 421

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.

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

1. Remove the V-belts. REMOVAL, V-belt. >
2. Remove the crank pulley. REMOVAL, Crank Pulley. >
3. Remove the timing belt cover. REMOVAL, Timing Belt Cover. >
4. Remove the timing belt. REMOVAL, Timing Belt. >
5. Remove the 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 422

ST 499977500 CAM SPROCKET WRENCH

Scheme 423

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. INSTALLATION, Timing Belt. >
4. Install the timing belt cover. INSTALLATION, Timing Belt Cover. >
5. Install the crank pulley. INSTALLATION, Crank Pulley. >
6. Install the V-belts. INSTALLATION, V-belt. >

1. Check the cam sprocket teeth for abnormal wear and scratches.
2. Make sure there is no free play between cam sprocket and key.

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

1. Remove the V-belts. REMOVAL, V-belt. >
2. Remove the crank pulley. REMOVAL, Crank Pulley. >
3. Remove the timing belt cover. REMOVAL, Timing Belt Cover. >
4. Remove the timing belt. REMOVAL, Timing Belt. >
5. Remove the crank sprocket.

Scheme 424

1. Install the crank sprocket.
2. Install the timing belt. INSTALLATION, Timing Belt. >
3. Install the timing belt cover. INSTALLATION, Timing Belt Cover. >
4. Install the crank pulley. INSTALLATION, Crank Pulley. >
5. Install the V-belts. INSTALLATION, V-belt. >

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

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

Scheme 425

Scheme 426

Scheme 427

Scheme 428

Scheme 429

Scheme 430

Scheme 431

1. Remove the V-belts. REMOVAL, V-belt. >
2. Remove the crank pulley. REMOVAL, Crank Pulley. >
3. Remove the timing belt cover. REMOVAL, Timing Belt Cover. >
4. Remove the timing belt. REMOVAL, Timing Belt. >
5. Remove the cam sprocket. REMOVAL, Cam Sprocket. >
6. Disconnect the oil flow control solenoid valve 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.
11. Disconnect the PCV hose from the rocker cover.
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 432

Scheme 433

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Scheme 436

Scheme 437

Scheme 438

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. INSTALLATION, Cam Sprocket. >
10. Install the timing belt. INSTALLATION, Timing Belt. >
11. Adjust the valve clearance. ADJUSTMENT, Valve Clearance. >
12. Install the rocker cover. Install the rocker cover gasket to the rocker cover. NOTE: Use a new rocker cover gasket. Apply liquid gasket to the specified point of the cylinder head. Apply extra amount of liquid gasket around semicircular plugs 5 mm or more. 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 (0.65 kgf-m, 4.7 ft-lb)
13. Connect the PCV hose to the rocker cover.
14. Connect the connector to the oil flow control solenoid valve.
15. Tighten the ignition coil.
16. Install the timing belt cover. INSTALLATION, Timing Belt Cover. >
17. Install the crank pulley. INSTALLATION, Crank Pulley. >
18. Install the V-belts. INSTALLATION, V-belt. >

Scheme 439

Scheme 440

Scheme 441

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 SPECIFICATION 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)

Scheme 442

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

Scheme 443

1. Remove the V-belts. REMOVAL, V-belt. >
2. Remove the intake manifold. REMOVAL , Intake Manifold . >
3. Remove the crank pulley. REMOVAL, Crank Pulley. >
4. Remove the timing belt cover. REMOVAL, Timing Belt Cover. >
5. Remove the timing belt. REMOVAL, Timing Belt. >
6. Remove the cam sprocket. REMOVAL, Cam Sprocket. >
7. Remove the bolt which installs the A/C compressor bracket on cylinder head.
8. Remove the secondary air combination valve. REMOVAL , Secondary Air Combination Valve . >
9. Remove the camshaft. REMOVAL, Camshaft. >
10. Remove the oil level gauge guide. (LH side)
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 444

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) Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
4. Install the camshaft. INSTALLATION, Camshaft. >
5. Install the secondary air combination valve. INSTALLATION , Secondary Air Combination Valve . >
6. Install the bolt of A/C compressor bracket to the cylinder head. Tightening torque: 36 N.m (3.7 kgf-m, 26.6 ft-lb)
7. Install the cam sprocket. INSTALLATION, Cam Sprocket. >
8. Install the timing belt. INSTALLATION, Timing Belt. >
9. Adjust the valve clearance. ADJUSTMENT, Valve Clearance. >
10. Install the rocker cover. Install the rocker cover gasket to the rocker cover. NOTE: Use a new rocker cover gasket. Apply liquid gasket to the specified point of the cylinder head. Apply extra amount of liquid gasket around semicircular plugs 5 mm or more. 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 (0.65 kgf-m, 4.7 ft-lb)
11. Install the timing belt cover. INSTALLATION, Timing Belt Cover. >
12. Install the crank pulley. INSTALLATION, Crank Pulley. >
13. Install the intake manifold. INSTALLATION , Intake Manifold . >
14. Install the V-belts. INSTALLATION, V-belt. >

DISASSEMBLY

1. Remove the valve lifter.
2. Place the cylinder head on ST1. ST1 498267600 CYLINDER HEAD TABLE
3. Using ST2, compress the valve spring and remove the valve spring retainer key. Remove each valve and valve spring.

ST2 499718000 VALVE SPRING REMOVER

Note. Mark each valve to prevent confusion. Pay careful attention not to damage the lips of intake valve oil seals and exhaust valve oil seals. Keep all the removed parts in order for re-installing in their original positions.

Scheme 445

Scheme 446

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

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.

Scheme 447

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)

Scheme 448

Scheme 449

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)

Scheme 450

Scheme 451

Scheme 452

Scheme 453

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.

Scheme 454

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 spring on a surface plate and measure its deflection at the top of spring using a try square.

VALVE SPRING LENGTH SPECIFICATION

Scheme 455

INTAKE AND EXHAUST VALVE OIL SEAL

1. For the following, replace the oil seal with a new part. See procedure 2 ) and «INSTALLATION»(/subaru/impreza-wrx/gh-2007-2010/remont/lubrication-system/#engine-lubrication-system-lubrication-h4dotc__installation) 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]

Scheme 456

Scheme 457

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 - 35.016 mm (1.3777 - 1.3786 in)

Scheme 458

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)

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

Scheme 459

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Scheme 467

1. Remove the V-belts. REMOVAL, V-belt. >
2. Remove the intake manifold. REMOVAL , Intake Manifold . >
3. Remove the crank pulley. REMOVAL, Crank Pulley. >
4. Remove the timing belt cover. REMOVAL, Timing Belt Cover. >
5. Remove the timing belt. REMOVAL, Timing Belt. >
6. Remove the cam sprocket. REMOVAL, Cam Sprocket. >
7. Remove the crank sprocket. REMOVAL, Crank Sprocket. >
8. Remove the generator and A/C compressor with their brackets.
9. Remove the camshaft. REMOVAL, Camshaft. >
10. Remove the cylinder head. REMOVAL, Cylinder Head. >
11. Remove the clutch disc and cover. (MT model) REMOVAL , Clutch Disc and Cover . >
12. Remove the flywheel. (MT model) REMOVAL , Flywheel . >
13. Remove the drive plate. (AT model) Using the ST, lock the crankshaft. ST 498497100 CRANKSHAFT STOPPER
14. Remove the oil separator cover.
15. Remove the water by-pass pipe for heater.
16. Remove the oil filter. REMOVAL , Engine Oil Filter . >
17. Remove the water pump. REMOVAL , Water Pump . >
18. 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.
19. 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.
20. Remove the front oil seal from the oil pump.
21. 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.
22. Remove the oil strainer.
23. Remove the baffle plate.
24. Remove the water pipe.
25. Remove the service hole plugs using a hexagon wrench [14 mm].
26. Remove the service hole cover.
27. 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.
28. 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.
29. Similarly remove the piston pins from #3 and #4 pistons.
30. Remove the cylinder block connecting bolt on the RH side.
31. Loosen the cylinder block connecting bolt on the LH side by 2-3 turns.
32. Set the part so that the cylinder block LH is on the upper side, and remove the cylinder block connecting bolt.
33. 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.
34. Remove the rear oil seal.
35. Remove the crankshaft together with connecting rod.
36. 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.
37. 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 468

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Scheme 492

Scheme 493

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.
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 (0.65 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 service hole plug 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. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
22. Install the water pipe. NOTE: Use new O-rings. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
23. Install the baffle plate. Tightening torque: 6.4 N.m (0.65 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, 7.2 ft-lb)
25. Tighten the oil strainer stay together with the baffle plate. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
26. 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)
27. 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 (0.65 kgf-m, 4.7 ft-lb)
28. Install the drive plate. (AT model) Using the ST, lock the crankshaft. ST 498497100 CRANKSHAFT STOPPER Tightening torque: 72 N.m (7.3 kgf-m, 53.1 ft-lb)
29. Install the flywheel. (MT model) INSTALLATION , Flywheel . >
30. Install the clutch disc and cover. (MT model) INSTALLATION , Clutch Disc and Cover . >
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 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 (0.65 kgf-m, 4.7 ft-lb)
32. Install the service hole plug 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)
33. Install the water by-pass pipe for heater. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
34. Install the oil filter. INSTALLATION , Engine Oil Filter . >
35. Install the cylinder head. INSTALLATION, Cylinder Head. >
36. Install the camshaft. INSTALLATION, Camshaft. >
37. Install the generator and A/C compressor with their brackets. Tightening torque: 36 N.m (3.7 kgf-m, 26.6 ft-lb)
38. Install the crank sprocket. INSTALLATION, Crank Sprocket. >
39. Install the cam sprocket. INSTALLATION, Cam Sprocket. >
40. Install the timing belt. INSTALLATION, Timing Belt. >
41. Adjust the valve clearance. ADJUSTMENT, Valve Clearance. >
42. Install the rocker cover. Install the rocker cover gasket to the rocker cover. NOTE: Use a new rocker cover gasket. Apply liquid gasket to the specified point of the cylinder head. Apply extra amount of liquid gasket around semicircular plugs 5 mm or more. 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 (0.65 kgf-m, 4.7 ft-lb)
43. Install the timing belt cover. INSTALLATION, Timing Belt Cover. >
44. Install the crank pulley. INSTALLATION, Crank Pulley. >
45. Install the intake manifold. INSTALLATION , Intake Manifold . >
46. Install the V-belts. INSTALLATION, V-belt. >

Scheme 494

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 495

1. Apply engine oil to the surface of the connecting rod bearings, and install to 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.

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)

Scheme 496

Scheme 497

Scheme 498

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 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. 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)

Scheme 499

Scheme 500

Scheme 501

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.

Scheme 502

Scheme 503

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 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.

PISTON RING AND GROOVE GAP 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 BEARING 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. Remove the bushing from connecting rod with ST and press. Press the bushing with the ST after applying oil on the periphery of new bushing. ST 499037100 CONNECTING ROD BUSHING REMOVER AND INSTALLER 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. After completion of reaming, clean the bushing to remove chips.

Scheme 509

Scheme 510

Scheme 511

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) Cylindrically 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) Cylindrically 0.006 mm (0.0002 in) Grinding limit (dia.) To 59.758 mm (2.3527 in) CRANK JOURNAL OUTER DIAMETER 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)

Refer to " CYLINDER HEAD " for removal and installation procedures of intake and exhaust valves. REMOVAL, Cylinder Head. > INSTALLATION, Cylinder Head. >

Refer to " CYLINDER BLOCK " for removal and installation procedures of pistons. REMOVAL, Cylinder Block. > INSTALLATION, Cylinder Block. >

Refer to " CYLINDER BLOCK " for removal and installation procedures of connecting rod. REMOVAL, Cylinder Block. > INSTALLATION, Cylinder Block. >

Refer to " CYLINDER BLOCK " for removal and installation procedures of the crankshaft. REMOVAL, Cylinder Block. > INSTALLATION, Cylinder Block. >

Note. The "RANK" shown in the chart shows the possibilities of the cause of trouble in order from "Very often" to "Rarely".

A - Very often

B - Sometimes

C - Rarely

PROBLEM SYMPTOM CHART

ENGINE NOISE POSSIBLE CAUSE CHART

See also:
• TIMING BELT
• INSTALLATION
• VALVE CLEARANCE
• CYLINDER HEAD