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

REMOVAL

1. Remove the engine assembly. Refer to «REMOVAL»(ref-357079-S13720948282010030800000) , Engine Assembly.
2. Remove the engine mounting from the engine assembly.

INSTALLATION

Install in the reverse order of removal.

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

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

Scheme 118

1. Remove the V-belt covers.
2. Remove the air intake duct. Refer to «REMOVAL»(ref-357076-S39226648372010030800000) , Air Intake Duct.
3. Loosen the bolt (A).
4. Loosen the slider bolt (B).
5. Remove the front side belt (C).

Scheme 119

1. Remove the front side belts. Refer to «FRONT SIDE BELT»(ref-357079-S07069179612010030800000) , REMOVAL, V-belt.
2. Cut the rear side belt with a wire cutter, etc. and discard.

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

Scheme 120

1. Remove the V-belts. Refer to «REMOVAL»(ref-357079-S26288262802010030800000) , V-belt.
2. Use the ST to lock the crank pulley, and remove the crank pulley bolt. ST 499977100 CRANK PULLEY WRENCH
3. Remove the crank pulley.

1. Install the crank pulley.
2. Use the ST to lock the crank pulley, and attach the crank pulley bolts. ST 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 by 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. Refer to «INSTALLATION»(ref-357079-S10185223112010030800000) , V-belt.

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

Scheme 121

1. Remove the secondary air pump. Refer to «REMOVAL»(ref-357078-S11886107782010030800000) , Secondary Air Pump.
2. Remove the V-belts. Refer to «REMOVAL»(ref-357079-S26288262802010030800000) , V-belt.
3. Remove the crank pulley. Refer to «REMOVAL»(ref-357079-S18693927572010030800000) , Crank Pulley.
4. Remove the timing belt cover LH (A).
5. Remove the timing belt cover RH (B) together with the engine harness cover.
6. Remove the front timing belt cover (C).

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) together with the engine harness cover. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
3. Install the timing belt cover LH (A). Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
4. Install the crank pulley. Refer to «INSTALLATION»(ref-357079-S32449958142010030800000) , Crank Pulley.
5. Install the V-belts. Refer to «INSTALLATION»(ref-357079-S10185223112010030800000) , V-belt.
6. Install the secondary air pump. Refer to «INSTALLATION»(ref-357078-S39618760082010030800000) , Secondary Air Pump.

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

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Scheme 130

1. Remove the V-belts. Refer to «REMOVAL»(ref-357079-S26288262802010030800000) , V-belt.
2. Remove the crank pulley. Refer to «REMOVAL»(ref-357079-S18693927572010030800000) , Crank Pulley.
3. Remove the timing belt cover. Refer to «REMOVAL»(ref-357079-S23272020472010030800000) , Timing Belt Cover.
4. Remove the timing belt guide.
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 marks on oil pump and notches of timing belt cover. 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.

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Scheme 133

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

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1. Prepare for installation of the automatic belt tension adjuster assembly. CAUTION: Always use a vertical type pressing tool to move the adjuster rod down. Do not use a lateral type vise. Push the adjuster rod vertically. Press-in the push adjuster rod gradually taking three minutes or more. Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lbf). Push in the adjuster rod to the end face of the cylinder. However, do not press the adjuster rod below the end face of the cylinder. Doing so may damage the cylinder. Do not release the press pressure until stopper pin is completely inserted. Attach the automatic belt tension adjuster assembly to vertical pressing tool. Slowly push in the adjuster rod with a pressure of 165 N (16.8 kgf, 37.1 lbf) 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) Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)

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1. Prepare for installation of the automatic belt tension adjuster assembly. Refer to «AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER»(ref-357079-S38980459572010030800000) , INSTALLATION, Timing Belt.
2. Align the mark (B) on crank sprocket with the mark (A) on oil pump.
3. Align the single line mark (B) on the exhaust cam sprocket RH with notch (A) on the timing belt cover.
4. Align the single line mark (B) on the intake cam sprocket RH with notch (A) on the timing belt cover. Make sure that the double line marks (C) on intake and exhaust cam sprockets are aligned.
5. Align the single line mark (B) on exhaust cam sprocket LH with notch (A) on the timing belt cover by turning the sprocket counterclockwise (as viewed from front of engine).
6. Align the single line mark (B) on intake cam sprocket LH with notch (A) on the timing belt cover by turning the sprocket clockwise (as viewed from front of engine). Make sure the double line marks (C) on the intake and exhaust cam sprockets are aligned.
7. Make sure that the cam and crank sprockets are positioned properly. CAUTION: Intake and exhaust camshafts for this DOHC engine can be independently rotated with the timing belts removed. As can be seen from the figure, if the intake and exhaust valves are lifted simultaneously, the valve heads will interfere with each other, resulting in bent valves. When the timing belts are not installed, four camshafts are held at the "zero-lift" position, where all cams on camshafts are not pushing down on the intake and exhaust valves. (Under this condition, all valves remain unlifted.) When the camshafts are rotated to install the timing belts, #2 intake and #4 exhaust cam of camshaft LH are held, pushing their corresponding valves down. (Under this condition, these valves are held lifted.) Camshaft RH are held so that their cams do not push the valves down. Camshafts LH must be rotated from the zero-lift position to the position where the timing belt is to be installed with the smallest possible angle, 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 valve 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. 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 bolt thread of cam sprocket section, (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 (0.7 kgf-m, 4.7 ft-lb) Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
12. Install the timing belt cover. Refer to «INSTALLATION»(ref-357079-S12377285842010030800000) , Timing Belt Cover.
13. Install the crank pulley. Refer to «INSTALLATION»(ref-357079-S32449958142010030800000) , Crank Pulley.
14. Install the V-belts. Refer to «INSTALLATION»(ref-357079-S10185223112010030800000) , V-belt.

Scheme 154

1. Check the timing belt teeth for breaks, cracks or wear. If any fault is found, replace the timing belt.
2. Check the condition on the back surface of the timing belt. If cracks are found, replace the timing belt. CAUTION: Be careful not to let oil, grease or coolant contact the timing belt. Remove quickly and thoroughly if this happens. Do not bend the timing belt sharply. In radial diameter h: 60 mm (2.36 in) or more

Scheme 155

1. Visually check the oil seals for leaks, and rod ends for abnormal wear and scratches. If necessary, replace the automatic belt tension adjuster assembly. NOTE: Slight traces of oil at the rod oil seal does not indicate a problem.
2. Check that the adjuster rod does not move when a pressure of 165 N (16.8 kgf, 37.1 lbf) is applied to it. This is to check adjuster rod stiffness.
3. If the adjuster rod is not stiff enough 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, and 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 the body. If it is not within specifications, replace the automatic belt tension adjuster assembly with a new part. Amount of rod protrusion H: 5.2 - 6.2 mm (0.205 - 0.244 in)

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

Scheme 156

1. Remove the V-belts. Refer to «REMOVAL»(ref-357079-S26288262802010030800000) , V-belt.
2. Remove the crank pulley. Refer to «REMOVAL»(ref-357079-S18693927572010030800000) , Crank Pulley.
3. Remove the timing belt cover. Refer to «REMOVAL»(ref-357079-S23272020472010030800000) , Timing Belt Cover.
4. Remove the timing belt. Refer to «REMOVAL»(ref-357079-S11805492022010030800000) , Timing Belt.
5. Remove the actuator covers of the intake and exhaust cam sprockets.
6. Fasten the cam sprocket and remove from the camshaft using ST. ST 499977500 CAM SPROCKET WRENCH

1. Fasten the cam sprocket and install to the camshaft using ST. NOTE: Do not confuse cam sprockets (LH) and (RH), and (INT) and (EXH) during installation. 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 covers of the intake and exhaust cam sprockets. NOTE: Use new O-rings. Tightening torque: 3.4 N.m (0.3 kgf-m, 2.5 ft-lb)
3. Install the timing belt. Refer to «INSTALLATION»(ref-357079-S40398684072010030800000) , Timing Belt.
4. Install the timing belt cover. Refer to «INSTALLATION»(ref-357079-S12377285842010030800000) , Timing Belt Cover.
5. Install the crank pulley. Refer to «INSTALLATION»(ref-357079-S32449958142010030800000) , Crank Pulley.
6. Install the V-belts. Refer to «INSTALLATION»(ref-357079-S10185223112010030800000) , V-belt.

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

Scheme 157

1. Remove the V-belts. Refer to «REMOVAL»(ref-357079-S26288262802010030800000) , V-belt.
2. Remove the crank pulley. Refer to «REMOVAL»(ref-357079-S18693927572010030800000) , Crank Pulley.
3. Remove the timing belt cover. Refer to «REMOVAL»(ref-357079-S23272020472010030800000) , Timing Belt Cover.
4. Remove the timing belt. Refer to «REMOVAL»(ref-357079-S11805492022010030800000) , Timing Belt.
5. Remove the crank sprocket.

1. Install the crank sprocket.
2. Install the timing belt. Refer to «INSTALLATION»(ref-357079-S40398684072010030800000) , Timing Belt.
3. Install the timing belt cover. Refer to «INSTALLATION»(ref-357079-S12377285842010030800000) , Timing Belt Cover.
4. Install the crank pulley. Refer to «INSTALLATION»(ref-357079-S32449958142010030800000) , Crank Pulley.
5. Install the V-belts. Refer to «INSTALLATION»(ref-357079-S10185223112010030800000) , V-belt.

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

Scheme 158

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Scheme 165

1. Remove the V-belts. Refer to «REMOVAL»(ref-357079-S26288262802010030800000) , V-belt.
2. Remove the crank pulley. Refer to «REMOVAL»(ref-357079-S18693927572010030800000) , Crank Pulley.
3. Remove the timing belt cover. Refer to «REMOVAL»(ref-357079-S23272020472010030800000) , Timing Belt Cover.
4. Remove the timing belt. Refer to «REMOVAL»(ref-357079-S11805492022010030800000) , Timing Belt.
5. Remove the cam sprocket. Refer to «REMOVAL»(ref-357079-S13058735912010030800000) , Cam Sprocket.
6. Disconnect the connector of the intake oil flow control solenoid valve.
7. Disconnect the connectors from the exhaust camshaft position sensor (A) and exhaust oil flow control solenoid valve (B).
8. Remove the timing belt cover No. 2 LH.
9. Remove the timing belt cover No. 2 RH. NOTE: Do not damage or lose the seal rubber when removing the timing belt covers.
10. Remove the tensioner bracket.
11. Remove the ignition coil. Refer to «REMOVAL»(ref-357093-S04223111392010030800000) , Ignition Coil.
12. Disconnect the PCV hose from the rocker cover. NOTE: For the PCV hose affixed with the clamp, fit the depression in the ST with the protrusion of the clamp as shown in the figure below, unlock the clamp and disconnect. ST 18353AA000 CLAMP PLIERS
13. Remove the rocker cover and gasket.
14. Remove the union screw without filter (without protrusion) which secures the oil pipe to the front camshaft cap.
15. Loosen the upper side of the front camshaft cap and the intake camshaft cap bolts equally, a little at a time in alphabetical sequence shown in the figure.
16. Loosen the lower side of the front camshaft cap and the exhaust camshaft cap bolts equally, a little at a time in alphabetical sequence shown in the figure.
17. Remove the front camshaft cap.
18. Remove the intake camshaft caps and intake camshaft.
19. Remove the exhaust camshaft caps and exhaust camshaft. NOTE: Arrange camshaft caps in order so that they can be installed in their original positions.
20. Remove the oil seal. CAUTION: Do not scratch the journal surface when removing the oil seal.
21. Similarly, remove the camshaft RH and related parts.

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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 the camshaft RH when installing the timing belt, but it is necessary to rotate the 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 thin coat of engine oil to the periphery of the camshaft oil seal and oil seal lip, and 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 to the front camshaft cap using the union screw without filter (without protrusion). Tightening torque: 29 N.m (3.0 kgf-m, 21.4 ft-lb)
5. Similarly, install the parts on right-hand side.
6. Install the tensioner bracket. Tightening torque: 24.5 N.m (2.5 kgf-m, 18.1 ft-lb)
7. Install the timing belt cover No. 2 RH. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
8. Install the timing belt cover No. 2 LH. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
9. Install the cam sprocket. Refer to «INSTALLATION»(ref-357079-S22743396672010030800000) , Cam Sprocket.
10. Install the timing belt. Refer to «INSTALLATION»(ref-357079-S40398684072010030800000) , Timing Belt.
11. Adjust the valve clearance. Refer to «ADJUSTMENT»(ref-357079-S30038380442010030800000) , 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. NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Install the rocker cover onto cylinder heads. Ensure the gasket is properly positioned during installation. Temporarily tighten the rocker cover bolts in alphabetical order shown in the figure, and then tighten to specified torque in alphabetical order. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
13. Connect the PCV hose to the rocker cover. NOTE: Use a new clamp for the PCV hose clamp, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp. ST 18353AA000 CLAMP PLIERS
14. Connect the connector to the intake oil flow control solenoid valve.
15. Connect the connectors to the exhaust camshaft position sensor (A) and exhaust oil flow control solenoid valve (B).
16. Install the ignition coil. Refer to «INSTALLATION»(ref-357093-S17087471812010030800000) , Ignition Coil.
17. Install the timing belt cover. Refer to «INSTALLATION»(ref-357079-S12377285842010030800000) , Timing Belt Cover.
18. Install the crank pulley. Refer to «INSTALLATION»(ref-357079-S32449958142010030800000) , Crank Pulley.
19. Install the V-belts. Refer to «INSTALLATION»(ref-357079-S10185223112010030800000) , V-belt.

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1. Measure the bend, and repair or replace if necessary. Camshaft bend limit: 0.020 mm (0.00079 in)
2. Check the journal for damage and wear. place if faulty.
3. Check the cutout portion used for camshaft sensor for damage. Replace if faulty.
4. Check the cam face condition, and remove the minor faults by grinding with oil stone. If offset wear occurs, replace it.
5. Measure the cam lobe height H and cam base circle diameter A. If it exceeds the standard or offset wear occurs, replace it. Cam lobe 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: Standard 37.0 mm (1.457 in)
6. Measure the outside diameter of camshaft journal. If the journal diameter is not within specification, 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)
7. Measure the oil clearance of camshaft journal. Clean the camshaft cap and the camshaft journal of the cylinder head. Place the camshaft on the cylinder head. (Without installing the valve lifter) Place a plastigage 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 plastigage on each journal. If oil clearance exceeds the standard, replace the camshaft. If necessary, replace the camshaft caps and cylinder head as a set. Camshaft oil clearance: Standard 0.037 - 0.072 mm (0.0015 - 0.0028 in) Completely remove the plastigage.
8. 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 0.068 - 0.116 mm (0.0027 - 0.0047 in)

Note. When replacing the single part, perform the work with the engine installed to body. Refer to INSPECTION , Valve Clearance. When performing the work with the engine installed to body, the following parts must also be removed/installed. Center exhaust pipe. Refer to REMOVAL , Center Exhaust Pipe. Refer to INSTALLATION , Center Exhaust Pipe. Turbocharger Refer to REMOVAL , Turbocharger. Refer to INSTALLATION , Turbocharger. Joint pipe Refer to REMOVAL , Joint Pipe. Refer to INSTALLATION , Joint Pipe. Front exhaust pipe Refer to REMOVAL , Front Exhaust Pipe. Refer to INSTALLATION , Front Exhaust Pipe.

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1. Remove the V-belts. Refer to «REMOVAL»(ref-357079-S26288262802010030800000) , V-belt.
2. Remove the intake manifold. Refer to «REMOVAL»(ref-357081-S32531544052010030800000) , Intake Manifold.
3. Remove the crank pulley. Refer to «REMOVAL»(ref-357079-S18693927572010030800000) , Crank Pulley.
4. Remove the timing belt cover. Refer to «REMOVAL»(ref-357079-S23272020472010030800000) , Timing Belt Cover.
5. Remove the timing belt. Refer to «REMOVAL»(ref-357079-S11805492022010030800000) , Timing Belt.
6. Remove the cam sprocket. Refer to «REMOVAL»(ref-357079-S13058735912010030800000) , Cam Sprocket.
7. Remove the secondary air combination valve. Refer to «REMOVAL»(ref-357078-S36146712352010030800000) , Secondary Air Combination Valve.
8. Remove the bolts which secure A/C compressor bracket to cylinder head.
9. Remove the oil pipe.
10. Remove the camshaft. Refer to «REMOVAL»(ref-357079-S20234831832010030800000) , Camshaft.
11. Remove the oil level gauge guide. (LH side only)
12. 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.
13. While tapping the cylinder head with a plastic hammer, separate it from cylinder block. Remove the bolts (A) and (D) to remove cylinder head.
14. Remove the cylinder head gasket. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block.
15. Similarly, remove the right side cylinder head.

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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. 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 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 again. CAUTION: The tightening angle of the bolt should not exceed 45°. Tighten bolts (A) and (B) further by 40 - 45°. CAUTION: Make sure the total "re-tightening angle" of the step ( 7 ) and ( 8 ) does not exceed 90°.
3. Install the oil level gauge guide. (LH side only) Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
4. Install the camshaft. Refer to «INSTALLATION»(ref-357079-S14967739122010030800000) , Camshaft.
5. Install the oil pipe. NOTE: Be careful of the install location of the union screw; the location will differ depending on whether or not there is a filter. Tightening torque: T1: 8 N.m (0.8 kgf-m, 5.9 ft-lb) T2: 29 N.m (3.0 kgf-m, 21.4 ft-lb)
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 secondary air combination valve. Refer to «INSTALLATION»(ref-357078-S37363632122010030800000) , Secondary Air Combination Valve.
8. Install the cam sprocket. Refer to «INSTALLATION»(ref-357079-S22743396672010030800000) , Cam Sprocket.
9. Install the timing belt. Refer to «INSTALLATION»(ref-357079-S40398684072010030800000) , Timing Belt.
10. Adjust the valve clearance. Refer to «ADJUSTMENT»(ref-357079-S30038380442010030800000) , Valve Clearance.
11. Install the rocker cover. Install the rocker cover gasket to the rocker cover. (Outer service information and ignition coil service information ) NOTE: Use a new rocker cover gasket. Apply liquid gasket to the specified point of the cylinder head. NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Install the rocker cover onto cylinder heads. Ensure the gasket is properly positioned during installation. Temporarily tighten the rocker cover bolts in alphabetical order shown in the figure, and then tighten to specified torque in alphabetical order. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
12. Connect the PCV hose to the rocker cover. NOTE: Use a new clamp for the PCV hose clamp, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp. ST 18353AA000 CLAMP PLIERS
13. Install the timing belt cover. Refer to «INSTALLATION»(ref-357079-S12377285842010030800000) , Timing Belt Cover.
14. Install the crank pulley. Refer to «INSTALLATION»(ref-357079-S32449958142010030800000) , Crank Pulley.
15. Install the intake manifold. Refer to «INSTALLATION»(ref-357081-S21642583932010030800000) , Intake Manifold.
16. Install the V-belts. Refer to «INSTALLATION»(ref-357079-S10185223112010030800000) , V-belt.

Scheme 181

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. For removal and installation procedures of the valve guide, intake valve oil seal and exhaust valve oil seal, refer to «VALVE GUIDE»(ref-357079-S28316163102010030800000) or «INTAKE AND EXHAUST VALVE OIL SEAL»(ref-357079-S40714686612010030800000) .

Scheme 182

1. Install the valve spring and valve. Coat the valve stem of each valve with engine oil and insert the valve into 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 cylinder head side. 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.

Scheme 183

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.

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

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

1. Remove the V-belts. Refer to «REMOVAL»(ref-357079-S26288262802010030800000) , V-belt.
2. Remove the intake manifold. Refer to «REMOVAL»(ref-357081-S32531544052010030800000) , Intake Manifold.
3. Remove the crank pulley. Refer to «REMOVAL»(ref-357079-S18693927572010030800000) , Crank Pulley.
4. Remove the timing belt cover. Refer to «REMOVAL»(ref-357079-S23272020472010030800000) , Timing Belt Cover.
5. Remove the timing belt. Refer to «REMOVAL»(ref-357079-S11805492022010030800000) , Timing Belt.
6. Remove the cam sprocket. Refer to «REMOVAL»(ref-357079-S13058735912010030800000) , Cam Sprocket.
7. Remove the crank sprocket. Refer to «REMOVAL»(ref-357079-S06739915842010030800000) , Crank Sprocket.
8. Remove the generator and A/C compressor with their brackets.
9. Remove the camshaft. Refer to «REMOVAL»(ref-357079-S20234831832010030800000) , Camshaft.
10. Remove the cylinder head. Refer to «REMOVAL»(ref-357079-S01792027112010030800000) , Cylinder Head.
11. Remove the clutch disc and cover. Refer to «REMOVAL»(ref-357082-S13608335812010030800000) , Clutch Disc and Cover.
12. Remove the flywheel. Refer to «REMOVAL»(ref-357082-S26608294832010030800000) , Flywheel.
13. Remove the oil separator cover.
14. Remove the water bypass pipe for heater.
15. Remove the oil filter. Refer to «REMOVAL»(ref-357094-S36214416262010030800000) , Engine Oil Filter.
16. Remove the oil cooler. Refer to «REMOVAL»(ref-357094-S38952284522010030800000) , Engine Oil Cooler.
17. Remove the water pump. Refer to «REMOVAL»(ref-357080-S16649019732010030800000) , Water Pump.
18. 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.
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 tank pipe assembly.
25. Remove the water pipe assembly.
26. Remove the service hole plugs using a hexagon wrench [14 mm].
27. Remove the service hole cover.
28. 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.
29. Draw out the piston pin from #1 and #2 pistons using ST. ST 499097700 PISTON PIN REMOVER ASSY NOTE: Be careful not to confuse the original combination of piston, piston pin and cylinder.
30. Similarly remove the piston pins from #3 and #4 pistons.
31. Remove the cylinder block connecting bolt on the RH side.
32. Loosen the cylinder block connecting bolt on the LH side by 2 to 3 turns.
33. Set the part so that the cylinder block LH is on the upper side, and remove the cylinder block connecting bolt.
34. 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.
35. Remove the rear oil seal.
36. Remove the crankshaft together with connecting rod.
37. 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.
38. 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 192

Scheme 193

Scheme 194

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

Scheme 202

Scheme 203

Scheme 204

Scheme 205

Scheme 206

Scheme 207

Scheme 208

Scheme 209

Scheme 210

Scheme 211

Scheme 212

Scheme 213

Scheme 214

Scheme 215

Scheme 216

Scheme 217

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) in the figure on the 180° opposite direction of (C).
18. Set the lower rail gap at position (G), located 120° clockwise from (C) in the figure. NOTE: Make sure ring gaps do not face the same direction. Make sure ring gaps are not within the piston skirt area.
19. Install the snap ring. Before positioning the piston on the cylinder block, attach the snap ring in the service hole of the cylinder block, and the piston hole on the opposite side. NOTE: Use new snap rings. Tightening torque: N.m (kgf-m, ft-lb) T: 70 (7.1, 51.6)
20. Install the piston. Set the parts so that the #1 and #2 cylinders are on the upper side. Using the ST1, turn the crankshaft so that #1 and #2 connecting rods are set at bottom dead center. ST1 499987500 CRANKSHAFT SOCKET Apply a coat of engine oil to the pistons and cylinders and insert pistons in their cylinders using ST2. ST2 498747300 PISTON GUIDE NOTE: Face the piston front mark towards the front of the engine.
21. Install the 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. 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 water tank pipe assembly. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
24. Install the baffle plate. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
25. Install the oil strainer. NOTE: Use new O-rings. Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb)
26. Tighten the oil strainer stay together with the baffle plate. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
27. Apply liquid gasket to the mating surfaces of oil pan, and install the oil pan. NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
28. Apply liquid gasket to the mating surface of oil separator cover and the threaded portion of bolt (A) shown in the figure (when reusing the bolt), and then install the oil separator cover. NOTE: Install within 5 min. after applying liquid gasket. Use new oil separator cover. Liquid gasket: Mating surface THREE BOND 1217G (Part No. K0877Y0100) or equivalent Bolt thread (A) (when reusing the bolt) THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
29. Install the flywheel. Refer to «INSTALLATION»(ref-357082-S13287467402010030800000) , Flywheel.
30. Install the clutch disc and cover. Refer to «INSTALLATION»(ref-357082-S01082425932010030800000) , 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: 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 bypass pipe for heater. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
34. Install the oil cooler. Refer to «INSTALLATION»(ref-357094-S38219214652010030800000) , Engine Oil Cooler.
35. Install the oil filter. Refer to «INSTALLATION»(ref-357094-S35657977492010030800000) , Engine Oil Filter.
36. Install the cylinder head. Refer to «INSTALLATION»(ref-357079-S03921376452010030800000) , Cylinder Head.
37. Install the camshaft. Refer to «INSTALLATION»(ref-357079-S14967739122010030800000) , Camshaft.
38. Install the generator and A/C compressor with their brackets. Tightening torque: 36 N.m (3.7 kgf-m, 26.6 ft-lb)
39. Install the crank sprocket. Refer to «INSTALLATION»(ref-357079-S32349496812010030800000) , Crank Sprocket.
40. Install the cam sprocket. Refer to «INSTALLATION»(ref-357079-S22743396672010030800000) , Cam Sprocket.
41. Install the timing belt. Refer to «INSTALLATION»(ref-357079-S40398684072010030800000) , Timing Belt.
42. Adjust the valve clearance. Refer to «ADJUSTMENT»(ref-357079-S30038380442010030800000) , Valve Clearance.
43. Install the rocker cover. Install the rocker cover gasket to the rocker cover. (Outer service information and ignition coil service information) NOTE: Use a new rocker cover gasket. Apply liquid gasket to the specified point of the cylinder head. NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Install the rocker cover onto cylinder heads. Ensure the gasket is properly positioned during installation. Temporarily tighten the rocker cover bolts in alphabetical order shown in the figure, and then tighten to specified torque in alphabetical order. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
44. Connect the PCV hose to the rocker cover. NOTE: Use a new clamp for the PCV hose clamp, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp. ST 18353AA000 CLAMP PLIERS
45. Install the timing belt cover. Refer to «INSTALLATION»(ref-357079-S12377285842010030800000) , Timing Belt Cover.
46. Install the crank pulley. Refer to «INSTALLATION»(ref-357079-S32449958142010030800000) , Crank Pulley.
47. Install the intake manifold. Refer to «INSTALLATION»(ref-357081-S21642583932010030800000) , Intake Manifold.
48. Install the V-belts. Refer to «INSTALLATION»(ref-357079-S10185223112010030800000) , V-belt.

Scheme 218

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 219

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

T: 52 (5.3, 38.4)

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 it with connecting rod bolt. 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 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.