Engine Mechanical (H4DOTC): Other Subaru Outback BP рестайлинг

CAUTION

1. Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work.
2. Remove contamination including dirt and corrosion before removal, installation or disassembly.
3. Keep the disassembled parts in order and protect them from dust and dirt.
4. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
5. Vehicle components are extremely hot after driving. Be wary of receiving bums from heated parts.
6. Be sure to tighten fasteners including bolts and nuts to the specified torque.
7. Place shop jacks or rigid racks at the specified points.
8. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery.
9. All parts should be thoroughly cleaned, paying special attention to engine oil passages, pistons and bearings.
10. Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to assembly.
11. Be careful not to let oil, grease or coolant contact the timing belt, clutch disc and flywheel.
12. All removed parts, if to be reused, should be reinstalled in the original positions and directions.
13. Bolts, nuts and washers should be replaced with new parts as required.
14. Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks.
15. Remove or install the engine in an area where chain hoists, lifting devices, etc. are available for ready use.
16. Be sure not to damage coated surfaces of body panels with tools, or not to stain seats and windows with coolant or oil. Place a cover over fender, as required, for protection.
17. Prior to starting work, prepare the following: Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc.
18. Lift-up or lower the vehicle when necessary. Make sure to support the correct positions.

GENERAL TOOL

GENERAL TOOL CHART

PROCEDURE

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

1. V-belt
2. Timing belt
3. Camshaft
4. Cylinder head

METHOD WITH SUBARU SELECT MONITOR

1. Before checking the ignition timing, check the following item: Check the air cleaner element is free from clogging, spark plugs are in good condition, and hoses are connected properly. Check the malfunction indicator light does not illuminate.
2. Warm-up the engine.
3. Stop the engine, and turn the ignition switch to OFF.
4. Connect the Subaru Select Monitor to the data link connector.
5. Turn the ignition switch to ON and run the Subaru Select Monitor.
6. Select {Each System Check} in Main Menu.
7. Select {Engine Control System} in Selection Menu.
8. Select {Current Data Display & Save} in Engine Control System Diagnosis.
9. Select {Data Display} in Data Display Menu.
10. Start the engine and check the ignition timing at idle speed. Ignition timing [BTDC/rpm]: 12°±10°/750 (MT Model) 17°±10°/750 (AT Model) If the timing is not correct, check the ignition control system. Refer to "Engine Control System". BASIC DIAGNOSTIC PROCEDURE . >

METHOD WITH TIMING LIGHT

1. Before checking the ignition timing, check the following item: Check the air cleaner element is free from clogging, spark plugs are in good condition, and hoses are connected properly. Check the malfunction indicator light does not illuminate.
2. Warm-up the engine.
3. Stop the engine, and turn the ignition switch to OFF.
4. Remove the air intake duct.
5. Disconnect the connector of the air flow meter.
6. Remove the air cleaner cover and element.
7. Connect the timing light alligator clip to the power wire of #1 ignition coil.
8. Install the air cleaner cover, element and airflow sensor.
9. Start the engine, turn the timing light to the crank pulley, and check the ignition timing by means of crank pulley indicator. Ignition timing [BTDC/rpm]: 12°±10°/750 (MT Model) 17°±10°/750 (AT Model) If the timing is not correct, check the ignition control system. Refer to "Engine Control System". BASIC DIAGNOSTIC PROCEDURE . >

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1. Remove the collector cover.
2. Warm-up the engine.
3. Disconnect the brake vacuum hose from intake manifold, and then install the vacuum gauge.
4. Keep the engine at idle speed and read the vacuum gauge indication. By observing the gauge needle movement, the internal condition of the engine can be diagnosed as described below. Vacuum pressure (at idling, A/C OFF): Less than -70.6 kPa (-530 mmHg, -20.85 inHg) (MT model) Less than -68.0 kPa (-510 mmHg, -20.08 inHg) (AT model) VACUUM GAUGE INDICATION CHART Diagnosis of engine condition by measurement of intake manifold vacuum Vacuum gauge Indication Possible engine condition 1. Needle is steady but lower than normal position. This tendency becomes more evident as engine temperature rises. Leakage around intake manifold gasket, or disconnected or damaged vacuum hose 2. Needle intermittently drops to position lower than normal position. Leakage around cylinder 3. Needle drops suddenly and intermittently from normal position. Sticky valve 4. When engine speed is gradually increased, needle begins to vibrate rapidly at certain speed, and then vibration increases as engine speed increases. Weak or broken valve springs 5. Needle vibrates above and below normal position in narrow range. Defective ignition system or throttle chamber idle adjustment

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1. Remove the collector cover.
2. Disconnect the ground cable from the battery.
3. Remove the oil pressure switch. REMOVAL , Oil Pressure Switch.>
4. Connect the oil pressure gauge hose to cylinder block.
5. Connect the battery ground cable to the battery.
6. Start the engine, and measure the oil pressure. Oil pressure: Standard: 98 kPa (1.0 kgf/cm 2 , 14 psi) or more (at 600 rpm) 294 kPa (3.0 kgf/cm 2 , 43 psi) or more (at 5,000 rpm) If the oil pressure is out of specification, check oil pump, oil filter and lubrication line. INSPECTION , Engine Lubrication System Trouble in General.> If the oil pressure warning light is ON and oil pressure is within specification, check the oil pressure switch. INSPECTION , Engine Lubrication System Trouble in General.> NOTE: Standard value is based on an engine oil temperature of 80°C (176°F).
7. After measuring the oil pressure, install the oil pressure switch. INSTALLATION , Oil Pressure Switch.> Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb)

FRONT SIDE BELT

1. Install the front side belt (C), and tighten the slider bolt so as to obtain the specified belt tension. INSPECTION, V-belt.>
2. Tighten the lock bolt (A).
3. Tighten the slider bolt (B). Tightening torque: Lock bolt (A): 25 N.m (2.5 kgf-m, 18.1 ft-lb) Slider bolt (B): 8 N.m (0.8 kgf-m, 5.9 ft-lb)
4. Install the collector cover bracket. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
5. Install the air intake duct. INSTALLATION , Air Intake Duct.>
6. Install the collector cover.

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1. Install the belt tensioner.
2. Install the rear side belt, and tighten the slider bolt (B) so as to obtain the specified belt tension. INSPECTION, V-belt.>
3. Tighten the lock nut (A). Tightening torque: Lock nut (A): 22.6 N.m (2.3 kgf-m, 16.6 ft-lb)
4. Install the front side belt. FRONT SIDE BELT, INSTALLATION, V-belt.>

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1. Replace the belts, if crack, fraying or wear is found.
2. Check the V-belt tension and adjust it if necessary by changing the generator installing position or idler pulley installing position. Belt tension (with belt tension gauge): (A) When installing new parts: 640 - 780 N (65 - 80 kgf, 144 - 175 lb) At inspection: 490 - 640 N (50 - 65 kgf, 110 - 144 lb) (B) When installing new parts: 650 - 750 N (66 - 76 kgf, 146 - 169 lb) At inspection: 350 - 450 N (36 - 46 kgf, 78 - 101 lb) Belt tension (when not using a belt tension gauge) (A) When installing new parts: 7 - 9 mm (0.276 - 0.354 in) At inspection: 9 - 11 mm (0.354 - 0.433 in) (B) When installing new parts: 7.5 - 8.5 mm (0.295 - 0.335 in) At inspection: 9.0 - 10.0 mm (0.354 - 0.394 in)

TIMING BELT

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

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1. Remove the V-belts. REMOVAL, V-belt.>
2. Remove the crank pulley. REMOVAL, Crank Pulley.>
3. Remove the timing belt cover. REMOVAL, Timing Belt Cover .>
4. Remove the timing belt guide. (MT model)
5. If the alignment mark or arrow mark (which indicates the direction of rotation) on timing belt fade away, put new marks before removing the timing belt as shown in procedures below. Turn the crankshaft using ST, and align the alignment marks on crank sprocket, intake cam sprocket (LH), exhaust cam sprocket (LH), intake cam sprocket (RH) and exhaust cam sprocket (RH) with notches of timing belt cover and cylinder block. ST 499987500 CRANKSHAFT SOCKET Using white paint, put alignment and/or arrow marks on timing belts in relation to the 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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1. Remove the belt idler (B) and (C).
2. Remove the belt idler No. 2.
3. Remove the automatic belt tension adjuster assembly.

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1. Prepare for installation of automatic belt tension adjuster assembly. CAUTION: Always use a vertical type pressing tool to move the adjuster rod down. Do not use a lateral type vise. Push the adjuster rod vertically. Press-in the push adjuster rod gradually taking three minutes or more. Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 1b). 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. Do not release the press pressure until stopper pin is completely inserted. Attach the automatic belt tension adjuster assembly to vertical pressing tool. Slowly move the adjuster rod down with a pressure of 294 N (30 kgf, 66 lb) or more until the adjuster rod is aligned with the stopper pin hole in the cylinder. With a 2 mm (0.08 in) dia. stopper pin or a 2 mm (nominal) dia. hex bar wrench inserted into the stopper pin hole in the cylinder, secure the adjuster rod.
2. Install the automatic belt tension adjuster assembly. Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb)
3. Install the belt idler No. 2. Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb)
4. Install the belt idlers. Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb)

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1. Prepare for installation of automatic belt tension adjuster assembly. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION, Timing Belt.>
2. Align the mark (A) on crank sprocket with the mark on oil pump cover at cylinder block.
3. Align single line mark (A) on the exhaust cam sprocket (RH) with notch (B) on timing belt cover.
4. Align single line mark (A) on the intake cam sprocket (RH) with notch (B) on timing belt cover. (Make sure that the double lines (C) on intake and exhaust camshaft sprockets are aligned.)
5. Align the single line mark (A) on exhaust cam sprocket (LH) with notch (B) on timing belt cover by turning the sprocket counterclockwise (as viewed from front of engine).
6. Align the single line mark (A) on intake cam sprocket (LH) with notch (B) on timing belt cover by turning the sprocket clockwise (as viewed from front of engine). Make sure the double line marks (C) on the intake and exhaust cam sprockets are aligned.
7. Make sure that the cam and crank sprockets are positioned properly. CAUTION: Intake and exhaust camshafts for this DOHC engine can be independently rotated with the timing belts removed. As can be seen from the figure, if the intake and exhaust valves are lifted simultaneously, the valve heads will interfere with each other, resulting in bent valves. When the timing belts are not installed, four camshafts are held at the "zero-lift" position, where all cams on camshafts do not push the intake and exhaust valves down. (Under this condition, all valves remain unlifted.) When the camshafts are rotated to install the timing belts, #2 intake and #4 exhaust cam of camshafts (LH) are held to push their corresponding valves down. (Under this condition, these valves are held lifted.) Right-side camshafts are held so that their cams do not push 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 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 3 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, 28.9 ft-lb) NOTE: Make sure that the marks on the timing belt and sprockets are aligned.
10. After ensuring that the marks on the timing belt and sprockets are aligned, remove the stopper pin from tensioner adjuster.
11. Install the timing belt guide. (MT model) NOTE: Clean the threaded portion of timing belt cover before attaching bolts. Apply liquid gasket to the threaded portion of cam sprocket, (when reusing bolts) Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent Temporarily tighten the bolts mounting the timing belt guide. Check and adjust the clearance between timing belt and timing belt guide. Clearance: 1.0±0.5 mm (0.039±0.020 in) Tighten the bolts mounting the timing belt guide. Tightening torque: 9.75 N.m (1.0 kgf-m, 7.2 ft-lb) Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
12. Install the timing belt cover. INSTALLATION, Timing Belt Cover.>
13. Install the crank pulley. INSTALLATION, Crank Pulley.>
14. Install the V-belts. INSTALLATION, V-belt.>

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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

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1. Visually check the oil seals for leaks, and rod ends for abnormal wear and scratches. If necessary, replace the automatic belt tension adjuster assembly. NOTE: Slight traces of oil on the oil seal of the rod does not indicate a problem.
2. Check that the adjuster rod does not move when a pressure of 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 cylinder. Repeat this operation two to three times. With the adjuster rod moved all the way up, apply a pressure of 294 N (30 kgf, 66 lb) to it. Check the adjuster rod stiffness. If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new part. CAUTION: Always use a vertical type pressing tool to move the adjuster rod down. Do not use a lateral type vise. Push the adjuster rod vertically. Press-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 1b). Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into cylinder. Doing so may damage the cylinder.
4. Measure the amount of rod protrusion "H" beyond the body. If it is not within specified range, replace with new part. Amount of rod protrusion H: 5.2 - 6.2 mm (0.205 - 0.244 in)

BELT TENSION PULLEY

1. Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. If defective, replace the belt tension pulley.
2. Check the belt tension pulley for smooth rotation. Replace if noise or excessive play occurs.
3. Check the belt tension pulley for grease leakage.

BELT IDLER

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

VALVE SEAT

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

Valve seat width W

Intake

Standard

0.6 - 1.4 mm (0.024 - 0.055 in)

Exhaust

Standard

1.2 - 1.8 mm (0.047 - 0.071 in)

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1. Check the clearance between valve guide and valve stem. The clearance can be checked by measuring respectively the outer diameter of valve stem with a micrometer and the inner diameter of valve guide with a caliper gauge. Clearance between the valve guide and valve stem: Standard Intake 0.030 - 0.057 mm (0.0012 - 0.0022 in) Exhaust 0.040 - 0.067 mm (0.0016 - 0.0026 in)
2. If the clearance between valve guide and valve stem exceeds the standard, replace the valve guide or valve itself whichever shows greater amount of wear or damaged and etc. See the following procedure for valve guide replacement. Valve guide inner diameter: 6.000 - 6.012 mm (0.2362 - 0.2367 in) Valve stem outer diameters: Intake 5.955 - 5.970 mm (0.2344 - 0.2350 in) Exhaust 5.945 - 5.960 mm (0.2341 - 0.2346 in) Place the cylinder head on ST1 with the combustion chamber upward so that valve guides fit the holes in ST1. Insert the ST2 into valve guide and press it down to remove the valve guide. ST1 498267600 CYLINDER HEAD TABLE ST2 499767200 VALVE GUIDE REMOVER Turn the cylinder head upside down and place the ST as shown in the figure. ST 18251AA020 VALVE GUIDE ADJUSTER Before installing a new valve guide, make sure that neither scratches nor damages exist on the inner surface of valve guide holes in cylinder head. Put a new valve guide, coated with sufficient oil, in cylinder, and insert the ST1 into valve guide. Press in until the valve guide upper end is flush with the upper surface of ST2. ST1 499767200 VALVE GUIDE REMOVER ST2 18251AA020 VALVE GUIDE ADJUSTER Check the valve guide protrusion. Valve guide protrusion L: 15.8 - 16.2 mm (0.622 - 0.638 in) Ream the inside of valve guide using ST. Put the ST in valve guide, and rotate the ST slowly clockwise while pushing it lightly. Bring the ST back while rotating it clockwise. NOTE: Apply engine oil to the ST when reaming. If the inner surface of valve guide is damaged, the edge of ST should be slightly ground with oil stone. If the inner surface of valve guide becomes lustrous and the ST does not chip, use a new ST or remedy the ST. After reaming, clean the valve guide to remove chips. Recheck the contact condition between valve and valve seat after replacing the valve guide. ST 499767400 VALVE GUIDE REAMER

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1. Inspect the flange and stem of valve, and replace the valve with a new part if damaged, worn, deformed, or if "H" is outside of the specified limit. Head edge thickness H: Standard Intake (A) 1.0 - 1.4 mm (0.039 - 0.055 in) Exhaust (B) 1.3 - 1.7 mm (0.051 - 0.067 in)
2. Put a small amount of grinding compound on the seat surface, and lap the valve and seat surface. Install a new intake valve oil seal after lapping. NOTE: It is possible to differentiate between the intake valve and the exhaust valve by their overall length. Valve overall length: Intake 104.4 mm (4.110 in) Exhaust 104.65 mm (4.1201 in)

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1. Check the valve springs for damage, free length, and tension. Replace the valve spring if it is not within the standard value presented in the table.
2. To measure the squareness of the valve spring, stand the spring on a surface plate and measure its deflection at the top of spring using a try square. VALVE SPRINGS SPECIFICATION Free length mm (in) 47.32(1.863) Tension/spring height N (kgf, lb)/mm (in) Set 205 - 235 (20.9 - 24.0, 46.1 - 52.8)/36.0 (1.417) Lift 426 - 490 (43.4 - 50.0, 95.8 - 110)/26.50 (1.041) Squareness 2.5°, 2.1 mm (0.083 in) or less

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1. For the following, replace the oil seal with a new part. See the ) and subsequent for replacement procedures. When the lip is damaged. When the spring is out of the specified position. When readjusting the surfaces of valve and valve seat. When replacing the valve guide.
2. Place the cylinder head on ST1.
3. Using the ST2, press in the oil seal. ST1 498267600 CYLINDER HEAD TABLE ST2 498857100 VALVE OIL SEAL GUIDE NOTE: Apply engine oil to oil seal before press-fitting. When press-fitting the oil seal, do not use a hammer or strike in. The intake valve oil seal and exhaust valve oil seal can be distinguished by colors. Color of rubber part: Intake [Gray] Exhaust [Green]

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1. Check the valve lifter visually.
2. Measure the outer diameter of valve lifter. Outer diameter: 34.959 - 34.975 mm (1.3763 - 1.3770 in)
3. Measure the inner diameter of valve lifter mating surface on cylinder head. Inner diameter: 34.994 - 35.016 mm (1.3777- 1.3786 in) NOTE: If difference between outer diameter of valve lifter and inner diameter of its mating surface is not within the standard or there is uneven wear, replace the cylinder head. Standard: 0.019 - 0.057 mm (0.0007 - 0.0022 in)

CYLINDER BLOCK

1. Check for cracks or damage. Use liquid penetrant tester on the important sections to check for fissures. Check that there are no marks of gas leaking or water leaking on gasket installing surface.
2. Check the oil passages for clogging.
3. Inspect the crankcase surface that mates with cylinder head for warping by using a straight edge, and correct by grinding if necessary. Warping limit: 0.025 mm (0.00098 in) Grinding limit: 0.1 mm (0.004 in) Standard height of cylinder block: 201.0 mm (7.91 in)

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1. The cylinder bore size is stamped on the front upper face of the cylinder block. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Standard sized pistons are classified into two grades, "A" and "B". These grades should be used as guide lines in selecting a standard piston. Standard diameter: A: 99.505 - 99.515 mm (3.9175 - 3.9179 in) B: 99.495 - 99.505 mm (3.9171 - 3.9175 in)
2. Cylinder inner diameter measurement Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights as shown in the figure, using a cylinder bore gauge. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Taper: Standard 0.015 mm (0.0006 in) Out-of-roundness: Standard 0.010 mm (0.0004 in)
3. When the piston is to be replaced due to general or cylinder wear, determine a suitable sized piston by measuring the piston clearance.
4. Cylinder outer diameter measurement Measure the outer diameter of each piston at the height as shown in the figure. (Thrust direction) NOTE: Measurement should be performed at a temperature of 20°C (68°F). Piston grade point H: 38.2 mm (1.50 in) Piston outer diameter: Standard A: 99.505 - 99.515 mm (3.9175 - 3.9179 in) B: 99.495 - 99.505 mm (3.9171 - 3.9175 in) 0.25 mm (0.0098 in) oversize 99.745 - 99.765 mm (3.9270 - 3.9278 in) 0.50 mm (0.0197 in) oversize 99.995 - 100.015 mm (3.9368 - 3.9376 in)
5. Calculate the clearance between cylinder and piston. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Cylinder to piston clearance at 20°C (68°F): Standard -0.010 - 0.010 mm (-0.00039 - 0.00039 in)
6. Boring and honing If any of the measured value of taper, out-of-roundness or cylinder-to-piston clearance is out of standard or if there is any damage on the cylinder wall, rebore it to replace with an oversize piston. CAUTION: When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and replaced with oversize pistons. Do not perform boring on one cylinder only. Do not replace only a single cylinder for an oversize piston. If the cylinder inner diameter exceeds the limit after boring and honing, replace the cylinder block. NOTE: Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, when measuring the cylinder diameter, wait until it has cooled to room temperature. Cylinder inner diameter boring limit (diameter): 100.015 mm (3.9376 in)

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1. Check the piston and piston pin for breaks, cracks or wear. Replace if faulty.
2. Check the piston ring groove for wear and damage. Replace if faulty.
3. Make sure that the piston pin can be inserted into the piston pin hole with a thumb at 20°C (68°F). Replace if faulty. Standard clearance between piston pin and hole in piston: Standard 0.004 - 0.008 mm (0.0002 - 0.0003 in)
4. Check the snap ring installation groove (A) on the piston for burr. If necessary, remove burr from the groove so that the piston pin can lightly move.
5. Check the piston pin snap ring for distortion, cracks and wear.

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1. If the piston ring is broken, damaged or worn, or if its tension is insufficient, or when the piston is replaced, replace the piston ring with a new part of the same size as piston. NOTE: The top ring and second ring have the mark to determine the direction to install on them. When installing the ring to piston, face this mark to the top side. Oil ring consists of the upper rail, expander and lower rail. When installing oil ring on piston, be careful of the direction of each rail.
2. Squarely place the piston ring and oil ring in cylinder using the piston, and measure the piston ring gap with a thickness gauge. PISTON RING SPECIFICATION Standard mm (in) Piston ring gap Top ring 0.20 - 0.25 (0.0079 - 0.0098) Second ring 0.37 - 0.52 (0.015 - 0.020) Oil ring rail 0.20 - 0.50 (0.0079 - 0.0197) NOTE: Difference between outer and inner circumference of top ring is within 0.05 mm (0.0020 in).
3. Fit the piston ring straight into the piston ring groove, then measure the clearance between piston ring and piston ring groove with a thickness gauge. NOTE: Before measuring the clearance, clean the piston ring groove and piston ring. PISTON RING GAP SPECIFICATION Standard mm (in) Clearance between piston ring and piston ring groove Top ring 0.040 - 0.080 (0.0016 - 0.0031) Second ring 0.030 - 0.070 (0.0012 - 0.0028)

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1. Replace the connecting rod, if the large or small end thrust surface is damaged.
2. Check for bend or twist using a connecting rod aligner. Replace the connecting rod if the bend or twist exceeds the limit. Limit of bend or twist per 100 mm (3.94 in) in length: 0.10 mm (0.0039 in)
3. Install the connecting rod fitted with bearing to the crankshaft, and measure the thrust clearance using a thickness gauge. If the thrust clearance exceeds the standard or uneven wear is found, replace the connecting rod. Connecting rod thrust clearance: Standard 0.070 - 0.330 mm (0.0028 - 0.0130 in)
4. Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc.
5. Measure the oil clearance on each connecting rod bearing using plastigauge. If any oil clearance is not within the standard, replace the defective bearing with a new part of standard size or under-size as necessary. (See the table below.) Connecting rod oil clearance: Standard 0.017 - 0.045 mm (0.0007 - 0.0018 in) CONNECTING ROD OIL CLEARANCE Unit: mm (in) Bearing Bearing size (Thickness at center) Outer diameter of crank pin Standard 1.490 - 1.502 (0.0587 - 0.0591) 51.984 - 52.000 (2.0466 - 2.0472) 0.03 (0.0012) undersize 1.504 - 1.512 (0.0592 - 0.0595) 51.954 - 51.970 (2.0454 - 2.0461) 0.05 (0.0020) undersize 1.514 - 1.522 (0.0596 - 0.0599) 51.934 - 51.950 (2.0447 - 2.0453) 0.25 (0.0098) undersize 1.614 - 1.622 (0.0635 - 0.0639) 51.734 - 51.750 (2.0368 - 2.0374)
6. Inspect the bushing at connecting rod small end, and replace with a new part if worn or damaged.
7. Measure the piston pin clearance at connecting rod small end. If the measured value is not within the standard, replace it with a new part. Clearance between piston pin and bushing: Standard 0 - 0.022 mm (0 - 0.0009 in)
8. The replacement procedure for the connecting rod small end bushing is as follows. Remove the bushing from connecting rod with ST and press. Press the bushing with the ST after applying oil on the periphery of new bushing. ST 499037100 CONNECTING ROD BUSHING REMOVER AND INSTALLER Make two 3 mm (0.12 in) holes in the pressed bushing by aligning with the pre-manufactured holes on the connecting rod, and ream the inside of the bushing. After completion of reaming, clean the bushing to remove chips.

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Scheme 454

Scheme 455

1. Clean the crankshaft completely, and check it for cracks through liquid penetrant testing, etc. If defective, replace the crankshaft.
2. Measure warping of the crankshaft. If it exceeds the limit, correct or replace it. NOTE: If a suitable V-block is not available, using just the #1 and #5 crankshaft bearings on cylinder block, position the crankshaft on cylinder block. Then, measure the crankshaft bend using a dial gauge. Crankshaft bend limit: 0.035 mm (0.0014 in)
3. Inspect the crank journal and crank pin for wear. If they are not within the specification, replace the bearing with a suitable (undersize) one, and replace or grind to correct the crankshaft as necessary. When grinding the crank journal or crank pin, finish them to the specified dimensions according to the undersize bearing to be used. Crank pin: Out-of-roundness 0.003 mm (0.0001 in) Cylindricality 0.004 mm (0.0002 in) Grinding limit (dia.) To 51.750 mm (2.0374 in) Crank journal: Out-of-roundness 0.005 mm (0.0002 in) Cylindricality 0.006 mm (0.0002 in) Grinding limit (dia.) To 59.758 mm (2.3527 in) CRANK JOURNAL SPECIFICATION Unit: mm (in) Crank journal diameter Crank pin outer diameter #1,#3 #2, #4, #5 Standard Journal O.D. 59.992 - 60.008 (2.3619 - 2.3625) 59.992 - 60.008 (2.3619 - 2.3625) 51.984 - 52.000 (2.0466 - 2.0472) Bearing size (Thickness at center) 1.998 - 2.011 (0.0787 - 0.0792) 2.000 - 2.013 (0.0787 - 0.0793) 1.486 - 1.498 (0.0585 - 0.0590) 0.03 (0.0012) undersize Journal O.D. 59.962 - 59.978 (2.3607 - 2.3613) 59.962 - 59.978 (2.3607 - 2.3613) 51.954 - 51.970 (2.0454 - 2.0461) Bearing size (Thickness at center) 2.017 - 2.020 (0.0794 - 0.0795) 2.019 - 2.022 (0.0795 - 0.0796) 1.504 - 1.512 (0.0592 - 0.0595) 0.05 (0.0020) undersize Journal O.D. 59.942 - 59.958 (2.3599 - 2.3605) 59.942 - 59.958 (2.3599 - 2.3605) 51.934 - 51.950 (2.0447 - 2.0453) Bearing size (Thickness at center) 2.027 - 2.030 (0.0798 - 0.0799) 2.029 - 2.032 (0.0799 - 0.0800) 1.514 - 1.522 (0.0596 - 0.0599) 0.25 (0.0098) undersize Journal O.D. 59.742 - 59.758 (2.3520 - 2.3527) 59.742 - 59.758 (2.3520 - 2.3527) 51.734 - 51.750 (2.0368 - 2.0374) Bearing size (Thickness at center) 2.127 - 2.130 (0.0837 - 0.0839) 2.129 - 2.132 (0.0838 - 0.0839) 1.614 - 1.622 (0.0635 - 0.0639)
4. Measure the thrust clearance of crankshaft at center bearing by using thickness gauge. If clearance exceeds the standard, replace the bearing. Crankshaft thrust clearance: Standard 0.030 - 0.115 mm (0.0012 - 0.0045 in)
5. Inspect individual crankshaft bearings for signs of flaking, seizure, melting and wear.
6. Measure the oil clearance on each crankshaft bearing using plastigauge. If the measured value is out of standard, replace the defective bearing with an undersize one, and replace or grind to correct the crankshaft as necessary. Crankshaft oil clearance: Standard 0.010 - 0.030 mm (0.0004 - 0.0012 in)