Engine Mechanical (H4SO) (Except Sti): Removal & Installation Subaru Impreza GH

REMOVAL

1. Remove the engine assembly. Refer to «REMOVAL»(ref-357236-S03174653372010031100000) , Engine Assembly.
2. Remove the engine mounting from the 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.

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

Scheme 385

1. Remove the V-belts. Refer to «REMOVAL»(ref-357236-S14836131932010031100000) , V-belt.
2. Use the ST to lock the crank pulley, and remove the crank pulley bolts. ST 499977400 CRANK PULLEY WRENCH (AT MODEL) ST 499977100 CRANK PULLEY WRENCH (MT MODEL)
3. Remove the crank pulley.

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

1. Remove the V-belts. Refer to «REMOVAL»(ref-357236-S14836131932010031100000) , V-belt.
2. Remove the crank pulley. Refer to «REMOVAL»(ref-357236-S03660225752010031100000) , Crank Pulley.
3. Remove the timing belt cover LH.
4. Remove the front timing belt cover.

Scheme 386

Scheme 387

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-357236-S42124623352010031100000) , Crank Pulley.
4. Install the V-belts. Refer to «INSTALLATION»(ref-357236-S01465658632010031100000) , V-belt.

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

Scheme 388

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Scheme 393

1. Remove the V-belts. Refer to «REMOVAL»(ref-357236-S14836131932010031100000) , V-belt.
2. Remove the crank pulley. Refer to «REMOVAL»(ref-357236-S03660225752010031100000) , Crank Pulley.
3. Remove the timing belt cover. Refer to «REMOVAL»(ref-357236-S36954403142010031100000) , 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 mark (b) of oil pump, 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 No. 2 (B).
8. Remove the timing belt.

Scheme 394

Scheme 395

1. Remove the belt idler.
2. Remove the automatic belt tension adjuster assembly.

Scheme 396

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Scheme 399

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 (0.08 in) (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 idlers.

Tightening torque

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

Scheme 400

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Scheme 406

1. Prepare for installation of the automatic belt tension adjuster assembly. Refer to «AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER»(ref-357236-S21711184462010031100000) , INSTALLATION, Timing Belt.
2. Align the mark (B) on oil pump with the mark (A) on crank sprocket.
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. ST 1 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 No. 2 (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-357236-S22753045842010031100000) , Timing Belt Cover.
10. Install the crank pulley. Refer to «INSTALLATION»(ref-357236-S42124623352010031100000) , Crank Pulley.
11. Install the V-belts. Refer to «INSTALLATION»(ref-357236-S01465658632010031100000) , V-belt.

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

1. Remove the V-belts. Refer to «REMOVAL»(ref-357236-S14836131932010031100000) , V-belt.
2. Remove the crank pulley. Refer to «REMOVAL»(ref-357236-S03660225752010031100000) , Crank Pulley.
3. Remove the timing belt cover. Refer to «REMOVAL»(ref-357236-S36954403142010031100000) , Timing Belt Cover.
4. Remove the timing belt. Refer to «REMOVAL»(ref-357236-S03108112832010031100000) , Timing Belt.
5. Remove the camshaft position sensor. Refer to «REMOVAL»(ref-357240-S41687852642010031100000) , Camshaft Position Sensor.
6. Fasten the cam sprocket and remove from the camshaft using ST.

ST 18231AA010 CAM SPROCKET WRENCH

Note. CAM SPROCKET WRENCH (499207100) can also be used.

Scheme 407

ST 499207400 CAM SPROCKET WRENCH

Scheme 408

1. Fasten the cam sprocket and install to the camshaft using ST. NOTE: Do not confuse cam sprockets (LH) and (RH) during installation. They should be distinguished by the L or R indication. ST 18231AA010 CAM SPROCKET WRENCH NOTE: CAMSHAFT 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-357240-S21827258342010031100000) , Camshaft Position Sensor.
3. Install the timing belt. Refer to «INSTALLATION»(ref-357236-S17220510322010031100000) , Timing Belt.
4. Install the timing belt cover. Refer to «INSTALLATION»(ref-357236-S22753045842010031100000) , Timing Belt Cover.
5. Install the crank pulley. Refer to «INSTALLATION»(ref-357236-S42124623352010031100000) , Crank Pulley.
6. Install the V-belts. Refer to «INSTALLATION»(ref-357236-S01465658632010031100000) , V-belt.

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

1. Remove the V-belts. Refer to «REMOVAL»(ref-357236-S14836131932010031100000) , V-belt.
2. Remove the crank pulley. Refer to «REMOVAL»(ref-357236-S03660225752010031100000) , Crank Pulley.
3. Remove the timing belt cover. Refer to «REMOVAL»(ref-357236-S36954403142010031100000) , Timing Belt Cover.
4. Remove the timing belt. Refer to «REMOVAL»(ref-357236-S03108112832010031100000) , Timing Belt.
5. Remove the crank sprocket.

Scheme 409

1. Install the crank sprocket.
2. Install the timing belt. Refer to «INSTALLATION»(ref-357236-S17220510322010031100000) , Timing Belt.
3. Install the timing belt cover. Refer to «INSTALLATION»(ref-357236-S22753045842010031100000) , Timing Belt Cover.
4. Install the crank pulley. Refer to «INSTALLATION»(ref-357236-S42124623352010031100000) , Crank Pulley.
5. Install the V-belts. Refer to «INSTALLATION»(ref-357236-S01465658632010031100000) , 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 .

1. Remove the high tension cord.
2. Disconnect the PCV hose and remove the rocker cover.
3. Remove the valve rocker assembly.

Scheme 410

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Scheme 412

1. Use the ST to rotate the spring stopper in the direction of the arrow to remove it from adjuster pin. ST 18258AA000 SPRING INSTALLER
2. 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.
3. Remove the valve rocker assembly.

Note. Set the ST in the position shown in the drawing to remove the intake valve rocker assembly.

ST 18354AA000 VALVE ROCKER HOLDER

Scheme 413

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Scheme 417

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 drawing 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. Remove the timing belt cover LH.
3. Adjust the valve clearance. Refer to «ADJUSTMENT»(ref-357236-S07580032192010031100000) , Valve Clearance.
4. Install the timing belt cover LH.
5. 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 order shown in the figure, tighten them in two stages. Tightening torque: First 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) Second (only (a) and (b) are tightened) 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) RH side LH side Connect the PCV hose.
6. Install the high tension cord.

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 418

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Scheme 421

Scheme 422

1. Remove the V-belts. Refer to «REMOVAL»(ref-357236-S14836131932010031100000) , V-belt.
2. Remove the crank pulley. Refer to «REMOVAL»(ref-357236-S03660225752010031100000) , Crank Pulley.
3. Remove the timing belt cover. Refer to «REMOVAL»(ref-357236-S36954403142010031100000) , Timing Belt Cover.
4. Remove the timing belt. Refer to «REMOVAL»(ref-357236-S03108112832010031100000) , Timing Belt.
5. Remove the cam sprocket. Refer to «REMOVAL»(ref-357236-S28550982012010031100000) , 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-357236-S03607569192010031100000) , 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.

Scheme 423

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Scheme 431

Scheme 432

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-357236-S15819682452010031100000) , 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-357236-S00130281272010031100000) , Cam Sprocket.
11. Install the timing belt. Refer to «INSTALLATION»(ref-357236-S17220510322010031100000) , Timing Belt.
12. Adjust the valve clearance. Refer to «ADJUSTMENT»(ref-357236-S07580032192010031100000) , 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 order shown in the figure, tighten them in two stages. Tightening torque: First 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) Second (only (a) and (b) are tightened) 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) RH side LH side Connect the PCV hose.
14. Install the high tension cord.
15. Install the timing belt cover. Refer to «INSTALLATION»(ref-357236-S22753045842010031100000) , Timing Belt Cover.
16. Install the crank pulley. Refer to «INSTALLATION»(ref-357236-S42124623352010031100000) , Crank Pulley.
17. Install the V-belts. Refer to «INSTALLATION»(ref-357236-S01465658632010031100000) , V-belt.

Scheme 433

Scheme 434

1. Measure the bend, and repair or replace if necessary. Camshaft bend limit: 0.025 mm (0.00098 in)
2. Check the journal for damage and wear. Replace if faulty.
3. Check the cam face condition, and remove the minor faults by grinding with oil stone. If offset wear occurs, replace it.
4. Measure the cam lobe height H, cam base circle diameter A and base circle step of adjacent intake cams (low speed and high speed). If it exceeds the standard or offset wear occurs, replace it. Cam lobe height H: CAM LOBE 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: Standard 34.00 mm (1.3386 in) Base circle step of adjacent intake cams (low speed and high speed): Standard 0.03 mm (0.001 in) or less
5. 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. CAMSHAFT JOURNAL 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)
6. Measure the thrust clearance with setting the dial gauge at end surface 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.

Camshaft thrust clearance

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 . When performing the work with the engine installed to body, the following parts must also be removed/installed.

1. Front exhaust pipe Refer to «REMOVAL»(ref-357254-S15303422132010031100000) , Front Exhaust Pipe. Refer to «INSTALLATION»(ref-357254-S20749004742010031100000) , Front Exhaust Pipe.

Scheme 435

1. Remove the V-belts. Refer to «REMOVAL»(ref-357236-S14836131932010031100000) , V-belt.
2. Remove the intake manifold. Refer to «REMOVAL»(ref-357240-S40421232002010031100000) , Intake Manifold.
3. Remove the crank pulley. Refer to «REMOVAL»(ref-357236-S03660225752010031100000) , Crank Pulley.
4. Remove the timing belt cover. Refer to «REMOVAL»(ref-357236-S36954403142010031100000) , Timing Belt Cover.
5. Remove the timing belt. Refer to «REMOVAL»(ref-357236-S03108112832010031100000) , Timing Belt.
6. Remove the cam sprocket. Refer to «REMOVAL»(ref-357236-S28550982012010031100000) , Cam Sprocket.
7. Remove the bolts which secure A/C compressor bracket to cylinder head.
8. Remove the valve rocker assembly. Refer to «REMOVAL»(ref-357236-S03607569192010031100000) , Valve Rocker Assembly.
9. Remove the camshaft. Refer to «REMOVAL»(ref-357236-S34800006232010031100000) , 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 436

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. Retighten 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-357236-S04708604582010031100000) , Camshaft.
5. Install the valve rocker assembly. Refer to «INSTALLATION»(ref-357236-S15819682452010031100000) , 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-357236-S00130281272010031100000) , Cam Sprocket.
8. Install the timing belt. Refer to «INSTALLATION»(ref-357236-S17220510322010031100000) , Timing Belt.
9. Adjust the valve clearance. Refer to «ADJUSTMENT»(ref-357236-S07580032192010031100000) , 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 order shown in the figure, tighten them in two stages. Tightening torque: First 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) Second (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-357236-S22753045842010031100000) , Timing Belt Cover.
12. Install the crank pulley. Refer to «INSTALLATION»(ref-357236-S42124623352010031100000) , Crank Pulley.
13. Install the intake manifold. Refer to «INSTALLATION»(ref-357240-S27066314622010031100000) , Intake Manifold.
14. Install the V-belts. Refer to «INSTALLATION»(ref-357236-S01465658632010031100000) , V-belt.

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

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Scheme 445

1. Remove the V-belts. Refer to «REMOVAL»(ref-357236-S14836131932010031100000) , V-belt.
2. Remove the intake manifold. Refer to «REMOVAL»(ref-357240-S40421232002010031100000) , Intake Manifold.
3. Remove the crank pulley. Refer to «REMOVAL»(ref-357236-S03660225752010031100000) , Crank Pulley.
4. Remove the timing belt cover. Refer to «REMOVAL»(ref-357236-S36954403142010031100000) , Timing Belt Cover.
5. Remove the timing belt. Refer to «REMOVAL»(ref-357236-S03108112832010031100000) , Timing Belt.
6. Remove the crank sprocket. Refer to «REMOVAL»(ref-357236-S14872101352010031100000) , Crank Sprocket.
7. Remove the generator and A/C compressor with their brackets.
8. Remove the cylinder head. Refer to «REMOVAL»(ref-357236-S27483393122010031100000) , Cylinder Head.
9. Use the ST to lock the crankshaft, and remove the drive plate. (AT model) ST 498497100 CRANKSHAFT STOPPER
10. Remove the clutch disc and cover. (MT model) Refer to «REMOVAL»(ref-357242-S42495094102010031100000) , Clutch Disc and Cover.
11. Remove the flywheel. (MT model) Refer to «REMOVAL»(ref-357242-S37047754282010031100000) , Flywheel.
12. Remove the oil separator cover.
13. Remove the water by-pass pipe for heater.
14. Remove the water pump. Refer to «REMOVAL»(ref-357238-S23416066712010031100000) , Water Pump.
15. Remove the bolts which secure oil pump to cylinder block. NOTE: When disassembling and checking the oil pump, loosen the relief valve plug before removing the oil pump.
16. 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.
17. Remove the front oil seal from the oil pump.
18. 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.
19. Remove the oil strainer.
20. Remove the baffle plate.
21. Remove the oil filter. Refer to «REMOVAL»(ref-357256-S00238273162010031100000) , Engine Oil Filter.
22. Remove the water pipe assembly.
23. Remove the service hole plugs using a hexagon wrench [14 mm].
24. Remove the service hole cover.
25. 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.
26. 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.
27. Similarly draw out the piston pins from #3 and #4 pistons.
28. Remove the cylinder block connecting bolt on the RH side.
29. Loosen the cylinder block connecting bolt on the LH side by 2 to 3 turns.
30. Set the part so that the cylinder block LH is on the upper side, and remove the cylinder block connecting bolt.
31. Separate the cylinder block LH and RH. NOTE: When separating the cylinder block, do not allow the connecting rod to fall or damage the cylinder block.
32. Remove the rear oil seal.
33. Remove the crankshaft along with the connecting rods.
34. Remove the crankshaft bearings from cylinder block using a hammer handle. NOTE: Press the crankshaft bearing at the end opposite to locking lip to remove. Be careful not to confuse the crankshaft bearing combination.
35. Remove each piston from the cylinder block using a wooden bar or hammer handle.

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

Scheme 446

Scheme 447

Scheme 448

Scheme 449

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Scheme 451

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Scheme 454

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Scheme 461

Scheme 462

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Scheme 466

Scheme 467

Scheme 468

Scheme 469

Scheme 470

Scheme 471

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 the LH side (A - H) in alphabetical order. Tightening torque: (A) - (G): 25 N.m (2.5 kgf-m, 18.4 ft-lb) (H): 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
12. Apply a coat of engine oil to the oil seal periphery and 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). 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. Tightening torque: N.m (kgf-m, ft-lb) T: 70 (7.1,51.6) 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 the 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 service hole plug and gasket. NOTE: Use a new gasket. Tightening torque: 70 N.m (7.1 kgf-m, 51.6 ft-lb) Tightening torque: N.m (kgf-m, ft-lb) T1: 6.4 (0.7,4.7) T2: 70 (7.1,51.6) Set the parts so that the #3 and #4 cylinders are on the upper side. Following the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins. Install the service hole cover. NOTE: Use new O-rings. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
22. Install the water pipe assembly. NOTE: Use new O-rings. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
23. Install the 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 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 new oil separator cover. Liquid gasket: Mating surface THREE BOND 1217G (Part No. K0877Y0100) or equivalent (A) bolt thread (when reusing bolts) THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
28. Use the ST to lock the crankshaft, and install the drive plate. (AT model) ST 498497100 CRANKSHAFT STOPPER Tightening torque: 72 N.m (7.3 kgf-m, 53.1 ft-lb)
29. Install the flywheel. (MT model) Refer to «INSTALLATION»(ref-357242-S04601542912010031100000) , Flywheel.
30. Install the clutch disc and cover. (MT model) Refer to «INSTALLATION»(ref-357242-S25639841322010031100000) , 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 mating surfaces 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-357256-S09078286652010031100000) , Engine Oil Filter.
35. Install the cylinder head. Refer to «INSTALLATION»(ref-357236-S34622717332010031100000) , 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-357236-S22789758092010031100000) , Crank Sprocket.
38. Install the timing belt. Refer to «INSTALLATION»(ref-357236-S17220510322010031100000) , Timing Belt.
39. Adjust the valve clearance. Refer to «ADJUSTMENT»(ref-357236-S07580032192010031100000) , Valve Clearance.
40. 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 order shown in the figure, tighten them in two stages. Tightening torque: First 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) Second (only (a) and (b) are tightened) 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) RH side LH side
41. Install the timing belt cover. Refer to «INSTALLATION»(ref-357236-S22753045842010031100000) , Timing Belt Cover.
42. Install the crank pulley. Refer to «INSTALLATION»(ref-357236-S42124623352010031100000) , Crank Pulley.
43. Install the intake manifold. Refer to «INSTALLATION»(ref-357240-S27066314622010031100000) , Intake Manifold.
44. Install the V-belts. Refer to «INSTALLATION»(ref-357236-S01465658632010031100000) , V-belt.

Scheme 472

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 473

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

T: 45 (4.6,33.2)

1. Apply engine 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 on connecting rod cap faces the 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.