Engine Mechanical (H4SO): Other Subaru Outback BP

CAUTION

1. Wear working clothing, including a cap, protective goggles, and protective shoes during operation.
2. Remove contamination including dirt and corrosion before removal, installation or disassembly.
3. Keep the disassembled parts in order and protect them from dust or dirt.
4. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement.
5. Be careful not to burn your hands, because each part in the vehicle is hot after running.
6. Be sure to tighten fasteners including bolts and nuts to the specified torque.
7. Place shop jacks or safety stands at the specified points.
8. Before disconnecting electrical connectors of sensors or units, be sure to disconnect ground cable from battery.
9. All parts should be thoroughly cleaned, paying special attention to the 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 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 ones as required.
14. Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks.
15. Remove or install 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 stain seats and windows with coolant or oil. Place a cover over fenders, 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.

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PROCEDURE

It is possible to conduct the following service procedures with engine on the vehicle, however, the procedures described in this section are based on the condition that the engine is removed from the vehicle.

1. V-belt
2. Timing Belt
3. Valve Rocker Assembly
4. Camshaft
5. Cylinder Head

FRONT SIDE BELT

Note. Perform the following procedures 1) to 4) with the engine installed to the body.

Scheme 210

Scheme 211

1. Remove V-belt cover.
2. Loosen the lock bolt (A).
3. Loosen the slider bolt (B).
4. Remove the front side belt (C).

Scheme 212

Scheme 213

1. Loosen the lock nut (A).
2. Loosen the slider bolt (B).
3. Remove the A/C belt.
4. Remove the A/C belt tensioner.

Scheme 214

1. Wipe off any oil or water on the belt and pulley.
2. Install a belt (C), and tighten the slider bolt so as to obtain the specified belt tension. Refer to «INSPECTION»(ref-208360-S12723956292005120700000) , V-belt.
3. Tighten the lock bolt (A).
4. Tighten slider bolt (B). Tightening torque: Lock bolt through bolt: 25 N.m (2.5 kgf-m, 18 ft-lb) Slider bolt: 8 N.m (0.8 kgf-m, 5.8 ft-lb)
5. Install V-belt cover.

Scheme 215

1. Install a belt, and tighten the slider bolt (B) so as to obtain the specified belt tension. Refer to «INSPECTION»(ref-208360-S12723956292005120700000) , V-belt.
2. Tighten the lock nut (A). Tightening torque: Lock nut (A): 22.6 N.m (2.3 kgf-m, 16.6 ft-lb)

WITHOUT BELT TENSION GAUGE

1. Replace belts, if cracks, fraying or wear is found.
2. Check drive belt tension and adjust it if necessary by changing generator installing position and/or idler pulley installing position. Belt tension (A) new: 7 - 9 mm (0.276 - 0.354 in) reused: 9 - 11 mm (0.354 - 0.433 in) (B)* new: 7.5 - 8.5 mm (0.295 - 0.335 in) reused: 9.0 - 10.0 mm (0.354 - 0.394 in)

Scheme 216

1. Replace belts, if cracks, fraying or wear is found.
2. Check drive belt tension and adjust it if necessary by changing generator installing position and or idler pulley installing position. Belt tension (A) 490 - 640 N (50 - 65 kgf, 110 - 144 lb) (B)* 350 - 450 N (36 - 46 kgf, 79 - 101 lb)

Scheme 217

1. Remove V-belt. Refer to «REMOVAL»(ref-208360-S13242530772005120700000) , V-BELT.
2. Remove crankshaft pulley bolt. To lock crankshaft, use ST. ST 499977100 CRANKSHAFT PULLEY WRENCH
3. Remove crankshaft pulley.

Scheme 218

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Scheme 220

1. Install crankshaft pulley.
2. Install pulley bolt. To lock crankshaft, use ST. ST 499977100 CRANKSHAFT PULLEY WRENCH Clean the crankshaft pulley thread using an air gun. Apply engine oil to the crankshaft pulley bolt seat and thread. Tighten the bolts temporarily with tightening torque of 44 N.m (4.5 kgf-m, 33 ft-lb). Tighten the crankshaft pulley bolts. Tightening torque: 177 N.m (18.0 kgf-m, 130.2 ft-lb)
3. Confirm that the tightening angle of the crankshaft pulley bolt is 65 degrees or more. If not, conduct the following procedures (1) through (4). Replace the crankshaft pulley bolts and clean them. Crankshaft pulley bolt: 12369AA011 Clean the crankshaft thread using an air gun. Apply engine oil to the crankshaft pulley bolt seat and thread. Tighten the bolts temporarily with tightening torque of 44 N.m (4.5 kgf-m, 33 ft-lb). Tighten the crankshaft pulley bolts keeping them in an angle between 65 degrees and 75 degrees. NOTE: Conduct the tightening procedures by confirming the turning angle of the crankshaft pulley bolt referring to the gauge indicated on the belt cover.
4. Install A/C belt tensioner.
5. Install A/C belt.

AUTOMATIC BELT TENSION ADJUSTER

1. Visually check oil seals for leaks, and rod ends for abnormal wear or scratches. If necessary, replace faulty parts.
2. Check that the adjuster rod does not move when a pressure of 294 N (30 kgf, 66 lb) is applied to it. This is to check adjuster rod stiffness.
3. If the adjuster rod is not stiff and moves freely when applying 294 N (30 kgf, 66 lb), check it using the following procedures: Slowly press the adjuster rod down to the end surface of the cylinder. Repeat this motion 2 or 3 times. With the adjuster rod moved all the way up, apply a pressure of 294 N (30 kgf, 66 lb) to it. Check adjuster rod stiffness. If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new one. CAUTION: Always use a vertical type pressing tool to move the adjuster rod down. Do not use a lateral type vise. Push adjuster rod vertically. Press-in the push adjuster rod gradually taking more than three minutes. Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lb). Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder.
4. Measure the extension of rod beyond the body. If it is not within specifications, replace with a new one.

Scheme 221

1. Rod extension: H 5.7+/-0.5 mm (0.224+/-0.020 in)

BELT TENSION PULLEY

1. Check mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace automatic belt tension adjuster assembly if faulty.
2. Check tension pulley for smooth rotation. Replace if noise or excessive play is noted.
3. Check tension pulley for grease leakage.

BELT IDLER

1. Check belt idler for smooth rotation. Replace if noise or excessive play is noted.
2. Check belt outer contacting surfaces of idler pulley for abnormal wear and scratches.
3. Check belt idler for grease leakage.

Scheme 222

1. Remove V-belt. Refer to «REMOVAL»(ref-208360-S13242530772005120700000) , V-BELT.
2. Remove crankshaft pulley. Refer to «REMOVAL»(ref-208360-S21251795552005120700000) , CRANKSHAFT PULLEY.
3. Remove belt cover. Refer to «REMOVAL»(ref-208360-S35879128732005120700000) , BELT COVER.
4. Remove timing belt assembly. Refer to «REMOVAL»(ref-208360-S07939121822005120700000) , TIMING BELT ASSEMBLY.
5. Remove camshaft position sensor. Refer to «REMOVAL»(ref-208357-S42486482762005120700000) , Camshaft Position Sensor.
6. Remove camshaft sprocket No. 1 and No. 2. To lock camshaft, use ST. ST 18231AA010 CAMSHAFT SPROCKET WRENCH NOTE: CAMSHAFT SPROCKET WRENCH (499207100) is also can be used.

Scheme 223

1. Install camshaft sprocket No. 1 and No. 2. To lock camshaft, use ST. ST 18231AA010 CAMSHAFT SPROCKET WRENCH NOTE: CAMSHAFT SPROCKET WRENCH (499207100) is also can be used. Tightening torque: 78 N.m (8.0 kgf-m, 57.9 ft-lb) CAUTION: Do not confuse left and right side camshaft sprockets during installation. The camshaft sprocket No. 2 is identified by a projection used to monitor camshaft position sensor.
2. Install timing belt assembly. Refer to «INSTALLATION»(ref-208360-S12148340212005120700000) , Timing Belt Assembly.
3. Install belt cover. Refer to «INSTALLATION»(ref-208360-S18673814782005120700000) , BELT COVER.
4. Install crankshaft pulley. Refer to «INSTALLATION»(ref-208360-S09900277832005120700000) , CRANKSHAFT PULLEY.
5. Install V-belt. Refer to «INSTALLATION»(ref-208360-S17941312302005120700000) , V-BELT.

CAMSHAFT SUPPORT

Measure the thrust clearance of camshaft with dial gauge. If the clearance exceeds the limit, replace camshaft support.

1. Standard: 0.030 - 0.090 mm (0.0012 - 0.0035 in)
2. Limit: 0.10 mm (0.0039 in)

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Scheme 226

1. Remove V-belt. Refer to «REMOVAL»(ref-208360-S13242530772005120700000), V-BELT.
2. Remove crankshaft pulley. Refer to «REMOVAL»(ref-208360-S21251795552005120700000), CRANKSHAFT PULLEY.
3. Remove belt cover. Refer to «REMOVAL»(ref-208360-S35879128732005120700000), BELT COVER.
4. Remove timing belt assembly. Refer to «REMOVAL»(ref-208360-S07939121822005120700000), TIMING BELT ASSEMBLY.
5. Remove camshaft sprocket. Refer to «REMOVAL»(ref-208360-S34341168092005120700000), CAMSHAFT SPROCKET.
6. Remove intake manifold. Refer to «REMOVAL»(ref-208357-S02061872362005120700000), Intake Manifold.
7. Remove bolt which installs A/C compressor bracket on cylinder head.
8. Remove valve rocker assembly. Refer to «REMOVAL»(ref-208360-S23225660322005120700000), VALVE ROCKER ASSEMBLY.
9. Remove camshaft. Refer to «REMOVAL»(ref-208360-S41661522882005120700000), CAMSHAFT.
10. Remove cylinder head bolts in alphabetical sequence (Scheme 226) NOTE: Leave bolts (a) and (c) engaged by three or four threads to prevent cylinder head from falling.
11. While tapping cylinder head with a plastic hammer, separate it from cylinder block.
12. Remove bolts (a) through (c) to remove cylinder head.
13. Remove cylinder head gasket. CAUTION: Do not scratch the mating surface of cylinder head and cylinder block.
14. Similarly, remove right side cylinder head.

Scheme 227

1. Install cylinder head and gaskets on cylinder block. CAUTION: Use new cylinder head gaskets. Be useful not to scratch the mating surface of cylinder block and cylinder head.
2. Tighten cylinder head bolts. Apply a coat of engine oil to washers and bolt threads. Tighten all bolts to 29 N.m (3.0 kgf-m, 22 ft-lb) in alphabetical sequence. Then tighten all bolts to 69 N.m (7.0 kgf-m, 51 ft-lb) in alphabetical sequence. Back off all bolts by 180° with reversing order of assembly and after that back them off by 180° again. Tighten bolts (a) and (b) to 34 N.m (3.5 kgf-m, 25 ft-lb). Tighten bolts (c), (d), (e) and (f) to 15 N.m (1.5 kgf-m, 11 ft-lb). Tighten all bolts by 80 to 90° in alphabetical sequence. CAUTION: Do not tighten bolts more than 90°. Further tighten all bolts by 80 to 90° in alphabetical sequence (Scheme 228) CAUTION: Ensure that the total "re-tightening angle" [in the former two steps], do not exceed 180°.
3. Install camshaft. Refer to «INSTALLATION»(ref-208360-S24847812732005120700000), Camshaft.
4. Install valve rocker assembly. Refer to «INSTALLATION»(ref-208360-S02895002322005120700000), VALVE ROCKER ASSEMBLY.
5. Install A/C compressor bracket on cylinder head.
6. Install intake manifold. Refer to «INSTALLATION»(ref-208357-S23219009012005120700000), Intake Manifold.
7. Install camshaft sprocket. Refer to «INSTALLATION»(ref-208360-S23395148232005120700000), CAMSHAFT SPROCKET.
8. Install timing belt assembly. Refer to «INSTALLATION»(ref-208360-S12148340212005120700000), Timing Belt Assembly.
9. Install belt cover. Refer to «INSTALLATION»(ref-208360-S18673814782005120700000), BELT COVER.
10. Install crankshaft pulley. Refer to «INSTALLATION»(ref-208360-S09900277832005120700000), CRANKSHAFT PULLEY.
11. Install V-belt. Refer to «INSTALLATION»(ref-208360-S17941312302005120700000), V-BELT.

Scheme 228

1. Place cylinder head on ST. ST 498267800 CYLINDER HEAD TABLE
2. Set ST on valve spring. Compress valve spring and remove the valve spring retainer key. Remove each valve and valve spring. ST 499718000 VALVE SPRING REMOVER NOTE: Mark each valve to prevent confusion. Use extreme care not to damage the lips of the intake valve oil seals and exhaust valve oil seals.

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Scheme 231

1. Installation of valve spring and valve Place cylinder head on ST. ST 498267800 CYLINDER HEAD TABLE Coat stem of each valve with engine oil and insert valve into valve guide. NOTE: When inserting valve into valve guide, use special care not to damage the oil seal lip. Install valve spring and retainer. NOTE: Be sure to install the valve springs with their close-coiled end facing the seat on the cylinder head. Set ST on valve spring. ST 499718000 VALVE SPRING REMOVER Compress valve spring and fit collet (valve). After installing, tap valve spring retainers lightly with wooden hammer for better seating.

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Scheme 233

1. Check valve springs for damage, free length, and tension. Replace valve spring if it is not to the specifications presented below.
2. To measure the squareness of the valve spring, stand the spring on a surface plate and measure its deflection at the top using a try square.

INTAKE AND EXHAUST VALVE OIL SEAL

If following conditions are found, use pliers to pinch oil seal and remove it from valve, and replace it new one.

1. Lip is damaged
2. Spring out of place
3. Reconditioning of surfaces for valve and valve seat is necessary
4. Replacement of valve guide is necessary

Scheme 234

1. Place cylinder head on ST1.
2. Press-fit oil seal to the specified dimension indicated in (Scheme 235) using ST2. CAUTION: Apply engine oil to oil seal before press-fitting. When press-fitting oil seal, do not use hammer or strike in. Differentiate between intake valve oil seal and exhaust valve oil seal by noting their difference in color. ST1 498267800 CYLINDER HEAD TABLE ST2 498857100 VALVE OIL SEAL GUIDE Color of rubber part: Intake [Black] Exhaust [Brown] Color of spring part: Intake [Silver] Exhaust [Silver]

Scheme 235

1. Make sure that no crack or other damage exists. In addition to visual inspection, inspect important areas by means of red lead check. Also make sure that gasket installing surface shows no trace of gas and water leaks.
2. Place cylinder head on ST. ST 498267800 CYLINDER HEAD TABLE
3. Measure the warping of the cylinder head surface that mates with crankcase using a straight edge and thickness gauge. If the warping exceeds 0.05 mm (0.0020 in), regrind the surface with a surface grinder. Warping limit: 0.05 mm (0.0020 in) Grinding limit: 0.1 mm (0.004 in) Standard height of cylinder head: 97.5 mm (3.839 in) NOTE: Uneven torque for the cylinder head bolts can cause warping. When reassembling, pay special attention to the torque so as to tighten evenly.

VALVE SEAT

Inspect intake and exhaust valve seats, and correct the contact surfaces with valve seat cutter if they are defective or when valve guides are replaced.

1. Valve seat width: W Intake (A) Standard: 1.1 mm (0.043 in) Limit: 1.8 mm (0.071 in) Exhaust (B) Standard: 1.5 mm (0.059 in) Limit: 2.2 mm (0.087 in)

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1. Check the clearance between valve guide and stem. The clearance can be checked by measuring the outside diameter of valve stem and the inside diameter of valve guide with outside and inside micrometers respectively. Clearance between the valve guide and valve stem: Standard Intake: 0.035 - 0.062 mm (0.0014 - 0.0024 in) Exhaust: 0.040 - 0.067 mm (0.0016 - 0.0026 in) Limit: 0.15 mm (0.0059 in)
2. If the clearance between valve guide and stem exceeds the limit, replace valve guide or valve itself whichever shows greater amount of wear. See 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: 5.950 - 5.965 mm (0.2343 - 0.2348 in) Exhaust: 5.945 - 5.960 mm (0.2341 - 0.2346 in) Place cylinder head on ST1 with the combustion chamber upward so that valve guides enter the holes in ST1. Insert ST2 into valve guide and press it down to remove valve guide. ST1 498267800 CYLINDER HEAD TABLE ST2 499767200 VALVE GUIDE REMOVER Turn cylinder head upside down and place ST (Scheme 242) Intake side: ST 499767700 VALVE GUIDE ADJUSTER Exhaust side: ST 499767800 VALVE GUIDE ADJUSTER Before installing new oversize valve guide, make sure that neither scratches nor damages exist on the inside surface of the valve guide holes in cylinder head. Put new valve guide, coated with sufficient oil, in cylinder, and insert 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 Intake side: ST2 499767700 VALVE GUIDE ADJUSTER Exhaust side: ST2 499767800 VALVE GUIDE ADJUSTER Check the valve guide protrusion. Valve guide protrusion: L Intake: 20.0 - 20.5 mm (0.787 - 0.807 in) Exhaust: 16.5 - 17.0 mm (0.650 - 0.669 in) Ream the inside of valve guide with ST. Slowly rotate the reamer clockwise while pressing it lightly into valve guide, and return it also rotating clockwise. After reaming, clean valve guide to remove chips. NOTE: Apply engine oil to the reamer when reaming. If the inner surface of the valve guide is torn, the edge of the reamer should be slightly ground with an oil stone. If the inner surface of the valve guide becomes lustrous and the reamer does not chips, use a new reamer or remedy the reamer. ST 499767400 VALVE GUIDE REAMER Recheck the contact condition between valve and valve seat after replacing valve guide.

Scheme 245

1. Inspect the flange and stem of valve, and replace if damaged, worn, or deformed, or if "H" is less than the specified limit. H: Intake Standard: 1.0 mm (0.039 in) Limit: 0.6 mm (0.024 in) Exhaust Standard: 1.2 mm (0.047 in) Limit: 0.6 mm (0.024 in) Valve overall length: Intake: 120.6 mm (4.75 in) Exhaust: 121.7 mm (4.79 in)
2. Put a small amount of grinding compound on the seat surface and lap the valve and seat surface. Refer to «ADJUSTMENT»(ref-208360-S18575385662005120700000) , Cylinder Head Assembly. Install a new intake valve oil seal after lapping.

CYLINDER BLOCK

1. Visually check for cracks and damage. Especially, inspect important parts by means of red lead check.
2. Check the oil passages for clogging.
3. Inspect crankcase surface that mates with cylinder head for warping by using a straight edge, and correct by grinding if necessary. Warping limit: 0.05 mm (0.0020 in) Grinding limit: 0.1 mm (0.004 in) Standard height of cylinder block: 201.0 mm (7.91 in)

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Scheme 248

1. The cylinder bore size is stamped on the cylinder block's front upper surface. CAUTION: Measurement should be performed at a temperature 20°C (68°F). NOTE: Standard sized pistons are classified into two grades, "A" and "B". These grades should be used as a guide line 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. How to measure the inner diameter of each cylinder Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the height shown in the figure, using a cylinder bore gauge. NOTE: Measurement should be performed at a temperature 20°C (68°F). Taper: Standard: 0.015 mm (0.0006 in) Limit: 0.050 mm (0.0020 in) Out-of-roundness: Standard: 0.010 mm (0.0004 in) Limit: 0.050 mm (0.0020 in)
3. When piston is to be replaced due to general or cylinder wear, determine a suitable sized piston by measuring the piston clearance.
4. How to measure the outer diameter of each position Measure the outer diameter of each piston at the height (Scheme 249) (Thrust direction) NOTE: Measurement should be performed at a temperature of 20°C (68°F). Piston grade point H: 37.0 mm (1.457 in) Piston outer diameter: Except U5 Standard A: 99.485 - 99.495 mm (3.9167 - 3.9171 in) B: 99.475 - 99.485 mm (3.9163 - 3.9167 in) 0.25 mm (0.0098 in) oversize: 99.725 - 99.735 mm (3.9262 - 3.9266 in) 0.50 mm (0.0197 in) oversize: 99.975 - 99.985 mm (3.9360 - 3.9364 in) U5 Standard: (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): Except U5 Standard: 0.010 - 0.030 mm (0.0004 - 0.0012 in) U5 Standard: 0.010 - 0.010 mm (0.0004 - 0.0004 in)
6. Boring and honing If the value of taper, out-of-roundness, or cylinder-to-piston clearance measured exceeds the specified limit or if there is any damage on the cylinder wall, rebore it to use an oversize piston. NOTE: When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and use oversize pistons. Do not perform boring on one cylinder only, nor use an oversize piston for one cylinder only. If the cylinder inner diameter exceeds the limit after boring and honing, replace the crankcase. NOTE: Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, pay attention to this when measuring the cylinder diameter. Limit of cylinder enlarging (boring): 0.5 mm (0.020 in)

Scheme 249

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Scheme 251

1. Check pistons and piston pins for damage, cracks, and wear and the piston ring grooves for wear and damage. Replace if defective.
2. Measure the piston-to-cylinder clearance at each cylinder. Refer to «CYLINDER AND PISTON»(ref-208360-S17750163462005120700000) , INSPECTION, Cylinder Block. If any of the clearances is not to specification, replace the piston or bore the cylinder to use an oversize piston.
3. Make sure that piston pin can be inserted into the piston pin hole with a thumb at 20°C (68°F). Replace if defective. Standard clearance between piston pin and hole in piston: Standard: 0.004 - 0.008 mm (0.0002 - 0.0003 in) Limit: 0.020 mm (0.0008 in)
4. Check snap ring installation groove on the piston for burr. If necessary, remove burr (A) from the groove so that piston pin can lightly move.
5. Check piston pin snap ring for distortion, cracks and wear.

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1. If piston ring is broken, damaged, or worn, or if its tension is insufficient, or when the piston is replaced, replace piston ring with a new one of the same size as the piston. NOTE: Marks are shown on the end of the top and second rings. When installing the rings to the piston, face this mark upward. Oil ring consists of upper rail, expander and lower rail. When installing on piston, be careful of each rail's direction.
2. Clean piston ring grove and piston ring.
3. Squarely place piston ring and oil ring in cylinder, and measure the piston ring gap with a thickness gauge.
4. Measure the clearance between piston ring and piston ring groove with a thickness gauge.

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Scheme 262

1. Replace connecting rod, if the large or small end thrust surface is damaged.
2. Check for bend or twist using a connecting rod aligner. Replace 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 connecting rod fitted with bearing to crankshaft and measure the side clearance (thrust clearance). Replace connecting rod if the side clearance exceeds the specified limit. Connecting rod side clearance: Standard: 0.070 - 0.330 mm (0.0028 - 0.0130 in) Limit: 0.4 mm (0.016 in)
4. Inspect connecting rod bearing for scar, peeling, seizure, melting, wear, etc.
5. Measure the oil clearance on individual connecting rod bearings by means of plastigage. If any oil clearance is not within specification, replace the defective bearing with a new one of standard size or undersize as necessary. (See the table below.) Connecting rod oil clearance: Standard: 0.016 - 0.044 mm (0.0006 - 0.0017 in) Limit: 0.050 mm (0.0020 in)
6. Inspect bushing at connecting rod small end, and replace if worn or damaged. Also measure the piston pin clearance at the connecting rod small end. Clearance between piston pin and bushing: Standard: 0 - 0.022 mm (0 - 0.0009 in) Limit: 0.030 mm (0.0012 in)
7. Replacement procedure is as follows. Remove bushing from connecting rod with ST and press. Press bushing with ST and press after applying oil on the periphery of bushing. ST 499037100 CONNECTING ROD BUSHING REMOVER AND INSTALLER Make two 3 mm (0.12 in) holes in bushing. Ream the inside of bushing. After completion of reaming, clean bushing to remove chips.

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1. Clean crankshaft completely and check for cracks by means of red lead check etc., and replace if defective.
2. Measure the crankshaft bend, and correct or replace if it exceeds the limit. CAUTION: If a suitable V-block is not available, install #1 and #5 crankshaft bearing on cylinder block, position crankshaft on these bearings and measure 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 specifications, replace bearing with a suitable (undersize) one, and replace or recondition crankshaft as necessary. When grinding crank journal or crank pin, finish them to the specified dimensions according to the undersize bearing to be used. Crank pin and crank journal: Out-of-roundness: 0.020 mm (0.0008 in) or less Taper limit: 0.07 mm (0.0028 in) Grinding limit: 0.250 mm (0.0098 in)
4. Measure the thrust clearance of crankshaft at center bearing. If the clearance exceeds the limit, replace bearing. Crankshaft thrust clearance: Standard: 0.030 - 0.115 mm (0.0012 - 0.0045 in) Limit: 0.25 mm (0.0098 in)
5. Inspect individual crankshaft bearings for signs of flaking, seizure, melting, and wear.
6. Measure the oil clearance on each crankshaft bearing by means of plastigage. If the measurement is not within the specification, replace defective bearing with an undersize one, and replace or recondition crankshaft as necessary.