Engine Mechanical (H4DOTC): Removal & Installation Subaru Outback BP рестайлинг

REMOVAL

1. Remove the engine unit. REMOVAL, Engine Assembly.>
2. Remove the engine mounting from engine assembly.

INSTALLATION

Install in the reverse order of removal.

Note. Make sure the engine mounting cover of the RH side is securely installed.

Tightening torque

Engine mounting

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

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

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1. Remove the collector cover.
2. Remove the air intake duct. REMOVAL , Air Intake Duct.>.
3. Remove the collector cover bracket.
4. Loosen the lock bolt (A).
5. Loosen the slider bolt (B).
6. Remove the front side belt (C).

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1. Remove the front side belts. FRONT SIDE BELT, REMOVAL, V-belt.>
2. Loosen the lock nut (A).
3. Loosen the slider bolt (B).
4. Remove the rear side belt.
5. Remove the belt tensioner.

Note. Wipe off any oil or water on the belt and pulley.

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

Scheme 308

1. Remove the V-belts. REMOVAL, V-belt.>
2. Remove the crank pulley bolt. To lock the crankshaft, use ST. ST 499977100 CRANK PULLEY WRENCH
3. Remove the crank pulley.

1. Install the crank pulley.
2. Install the pulley bolt. To lock the crankshaft, use ST. 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, 33 ft-lb). Tighten the crank pulley bolts. Tightening torque: 180 N.m (18.3 kgf-m, 132.7 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, 33 ft-lb). Tighten the crank pulley bolts 65° to 75°. NOTE: Conduct the tightening procedures by confirming the turning angle of crank pulley bolt referring to the gauge indicated on timing belt cover.
4. Install the belt tensioner.
5. Install the V-belts. INSTALLATION, V-belt.>

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

Scheme 309

1. Remove the secondary air pump. REMOVAL , Secondary Air Pump.>
2. Remove the V-belts. REMOVAL, V-belt.>
3. Remove the crank pulley. REMOVAL, Crank Pulley.>
4. Remove the timing belt cover (LH) (A).
5. Remove the timing belt cover (RH) (B).
6. Remove the front timing belt cover (C).

1. Install the front timing belt cover (C). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
2. Install the timing belt cover (RH) (B). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
3. Install the timing belt cover (LH) (A). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
4. Install the crank pulley. INSTALLATION, Crank Pulley.>
5. Install the V-belts. INSTALLATION, V-belt.>
6. Install the secondary air pump. INSTALLATION , Secondary Air Pump.>

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

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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. REMOVAL, Timing Belt.>
5. Remove the actuator cover of the intake cam sprocket.
6. Fasten the cam sprocket and remove from the cam shaft using ST. ST 499207400 CAM SPROCKET WRENCH ST 499977500 CAM SPROCKET WRENCH

1. Fasten the cam sprocket and install to the cam shaft using ST. NOTE: Do not confuse the cam sprockets (LH) and (RH) during installation. ST 499207400 CAM SPROCKET WRENCH Tightening torque: Tighten to 30 N.m (3.1 kgf-m, 22.1 ft-lb) of torque, and then tighten further by 45°. ST 499977500 CAM SPROCKET WRENCH Tightening torque: Tighten to 30 N.m (3.1 kgf-m, 22.1 ft-lb) of torque, and then tighten further by 45°.
2. Attach the actuator cover of the intake cam sprocket. NOTE: Use new O-rings. Tightening torque: 3.4 N.m (0.3 kgf-m, 2.5 ft-lb)
3. Install the timing belt. INSTALLATION, Timing Belt.>
4. Install the timing belt cover. INSTALLATION, Timing Belt Cover.>
5. Install the crank pulley. INSTALLATION, Crank Pulley.>
6. Install the V-belts. INSTALLATION, V-belt.>

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

Scheme 312

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

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

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

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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. REMOVAL, Timing Belt.>
5. Remove the cam sprocket. REMOVAL, Cam Sprocket.>
6. Disconnect the oil flow control solenoid valve assembly connector.
7. Remove the tensioner bracket.
8. Remove the timing belt cover No. 2 (LH).
9. Remove the timing belt cover No. 2 (RH).
10. Remove the ignition coil.
11. Disconnect the PCV hose from the rocker cover.
12. Remove the oil level gauge guide. (LH side)
13. Remove the rocker cover and gasket.
14. Remove the oil pipe.
15. Loosen the oil flow control solenoid valve assembly and intake camshaft cap bolts equally, a little at a time in alphabetical order shown in the figure.
16. Loosen the exhaust camshaft cap bolts equally, a little at a time in alphabetical order shown in the figure.
17. Remove the oil flow control solenoid valve assembly, intake camshaft cap and camshaft.
18. Remove the exhaust camshaft caps and camshaft. NOTE: Arrange camshaft caps in order so that they can be installed in their original positions.
19. Similarly, remove the camshafts (RH) and related parts.

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1. Install the camshaft. Apply engine oil to the cylinder head at camshaft bearing 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. It is necessary to rotate the camshaft (LH) slightly when installing the timing belt. Camshaft (RH) need not be rotated when set at the position shown in the figure. Intake camshaft (LH): Rotate 80° clockwise. Exhaust camshaft (LH): Rotate 45° counterclockwise.
2. Install the camshaft cap and oil flow control solenoid valve assembly. Apply small amount of liquid gasket to the mating surface of cap. NOTE: 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 1215 (Part No. 004403007) or equivalent Apply a thin coat of engine oil to the cap bearing surface, and install the cap to the camshaft according to the identification mark. Gradually tighten the camshaft cap and oil control valve assembly in at least two stages in alphabetical order shown in the figure, and then tighten to 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, 14.5 ft-lb) After tightening the camshaft cap, ensure the camshaft rotates only slightly while holding it at base circle.
3. Apply a coat of engine oil to the camshaft oil seal periphery and oil seal lips, then install the oil seal on the camshaft using ST1 and ST2. NOTE: Use a new oil seal. ST1 499587600 OIL SEAL INSTALLER ST2 499597200 OIL SEAL GUIDE
4. Install the rocker cover. Install the gasket on rocker cover. Install the peripheral gasket and ignition coil gasket. NOTE: Use a new gasket. Apply liquid gasket to the specified point of the cylinder head. NOTE: Apply extra amount of liquid gasket around semicircular plugs 5 mm or more. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent Install the rocker cover on cylinder head. Ensure the gasket is properly positioned during installation. Temporarily tighten the rocker cover tightening bolt in alphabetical sequence shown in the figure, and then tighten to specified torque in alphabetical order. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
5. Install the oil pipe. CAUTION: Install to the position shown in the figure as the head side and oil flow control solenoid valve side of union screw are of different specification. Tightening torque: 29 N.m (3.0 kgf-m, 21.4 ft-lb)
6. Connect the oil flow control solenoid valve connector.
7. Connect the PCV hose to the rocker cover.
8. Tighten the ignition coil.
9. Similarly, install the parts on right-hand side.
10. Install the tensioner bracket. Tightening torque: 24.5 N.m (2.5 kgf-m, 18.1 ft-lb)
11. Install the timing belt cover No. 2 (RH). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
12. Install the timing belt cover No. 2 (LH). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
13. Install the cam sprocket. INSTALLATION, Cam Sprocket.>
14. Install the timing belt. INSTALLATION, Timing Belt.>
15. Install the timing belt cover. INSTALLATION, Timing Belt Cover.>
16. Install the crank pulley. INSTALLATION, Crank Pulley.>
17. Install the V-belts. INSTALLATION, V-belt.>

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1. Measure the bend, and repair or replace if necessary. Service limit: 0.020 mm (0.0008 in) or less
2. Check the journal for damage and wear. Replace if faulty.
3. Measure the outside diameter of camshaft journal. If the journal diameter is not within the standard value, check the oil clearance. CAMSHAFT JOURNAL SPECIFICATION Camshaft journal Front Center, rear Standard mm (in) 37.946 - 37.963 (1.4939 - 1.4946) 29.946 - 29.963 (1.1790 - 1.1796)
4. Measurement of the camshaft journal oil clearance Clean the bearing caps and camshaft journals. Place the camshafts on cylinder head. (Without installing the valve lifter) Place a plastigauge across each camshaft journals. Gradually tighten the cap in at least two stages in alphabetical order shown in the figure, and then tighten to 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, 14.5 ft-lb) Remove the bearing caps. Measure the widest point of the plastigauge on each journal. If oil clearance exceeds the standard, replace the camshaft. If necessary, replace the camshaft caps and cylinder head as a set. Standard: 0.037 - 0.072 mm (0.0015 - 0.0028 in) Completely remove the plastigauge.
5. Check the cam face condition; remove the minor faults by grinding with oil stone. Measure the cam height H. If it exceeds the standard or offset wear occurs, replace it. Cam height H: Standard Intake 46.55 - 46.65 mm (1.833 - 7.537 in) Exhaust 46.75 - 46.85 mm (1.841 - 1.844 in) Cam base circle diameter A: 37.0 mm (1.457 in)
6. Measure the thrust clearance of camshaft with setting the dial gauge at end of camshaft. If the thrust clearance exceeds the standard or there is offset wear, replace the caps and cylinder head as a set. If necessary replace the camshaft. Standard: 0.068 - 0.116 mm (0.0027 - 0.0047 in)

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

Scheme 332

1. Remove the V-belts. REMOVAL, V-belt.>
2. Remove the crank pulley. REMOVAL, Crank Pulley.>
3. Remove the timing belt cover. REMOVAL, Timing Belt Cover.>
4. Remove the timing belt. REMOVAL, Timing Belt.>
5. Remove the cam sprocket. REMOVAL, Cam Sprocket.>
6. Remove the intake manifold. REMOVAL , Intake Manifold.>
7. Remove the secondary air combination valve. REMOVAL , Secondary Air Combi Valve.>
8. Remove the bolt which installs the A/C compressor bracket on cylinder head.
9. Remove the camshaft. REMOVAL, Camshaft.>
10. Remove the cylinder head bolts in alphabetical order shown in the figure. Leave the bolts (A) and (D) engaged by three or four threads to prevent the cylinder head from falling.
11. While tapping the cylinder head with a plastic hammer, separate it from cylinder block. Remove the bolts (A) and (D) to remove cylinder head.
12. Remove the cylinder head gasket. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block.
13. Similarly, remove the cylinder head (RH).

Scheme 333

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 gasket.
2. Tighten the cylinder head bolts. Apply a thin coat of engine oil to washer and bolt thread. Tighten all bolts to 29 N.m (3.0 kgf-m, 21.4 ft-lb) in alphabetical order. Further tighten all bolts to 69 N.m (7.0 kgf-m, 51 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 ft-lb) in alphabetical order. Tighten all bolts by 80 to 90° in alphabetical order. Tighten all bolts by 40 to 45° in alphabetical order. CAUTION: Do not tighten the bolts 45°. Further tighten the bolts (A) and (B) by 40 to 45°. CAUTION: Make sure that the total "re-tightening angle" of the previous steps (7) and (8) does not exceed 90°.
3. Install the camshaft. INSTALLATION, Camshaft.>
4. Install the A/C compressor bracket on cylinder head.
5. Install the secondary air combination valve. INSTALLATION , Secondary Air Combi Valve.>
6. Install the intake manifold. INSTALLATION , Intake Mani-fold.>
7. Install the cam sprocket. INSTALLATION, Cam Sprocket.>
8. Install the timing belt. INSTALLATION, Timing Belt.>
9. Install the timing belt cover. INSTALLATION, Timing Belt Cover.>
10. Install the crank pulley. INSTALLATION, Crank Pulley.>
11. Install the V-belts. INSTALLATION, V-belt.>

Scheme 334

1. Remove the valve lifter.
2. Compress the valve spring and remove the valve spring retainer key. Remove each valve and valve spring. ST1 498267600 CYLINDER HEAD TABLE ST2 499718000 VALVE SPRING REMOVER NOTE: Mark each valve to prevent confusion. Pay careful attention not to damage the lips of intake valve oil seals and exhaust valve oil seals. Keep all the removed parts in order for re-installing in their original positions.

Scheme 335

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

Scheme 336

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 crankcase 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.

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1. Remove the intake manifold. REMOVAL , Intake Manifold.>
2. Remove the V-belts. REMOVAL, V-belt.>
3. Remove the crank pulley. REMOVAL, Crank Pulley.>
4. Remove the timing belt cover. REMOVAL, Timing Belt Cover.>
5. Remove the timing belt. REMOVAL, Timing Belt.>
6. Remove the cam sprocket. REMOVAL, Cam Sprocket.>
7. Remove the crank sprocket. REMOVAL, Crank Sprocket.>
8. Remove the generator and A/C compressor with their brackets.
9. Remove the cylinder head. REMOVAL, Cylinder Head.>
10. Remove the clutch disc and cover. REMOVAL , Clutch Disc and Cover.>
11. Remove the flywheel. (MT model) REMOVAL , Flywheel.> ST 498497100 CRANKSHAFT STOPPER
12. Remove the drive plate. (AT model) Using the ST, lock the crankshaft. ST 498497100 CRANKSHAFT STOPPER
13. Remove the oil separator cover.
14. Remove the water by-pass pipe for heater.
15. Remove the oil filter. REMOVAL , Engine Oil Filter.>
16. Remove the oil cooler. REMOVAL , Engine Oil Filter.>
17. Remove the water pump. REMOVAL , Water Pump.>
18. Remove the bolts which install oil pump onto cylinder block. NOTE: When disassembling and checking the oil pump, loosen the relief valve plug before removing the oil pump.
19. Remove the oil pump from cylinder block using a flat tip screwdriver. CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump.
20. Remove the 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.
21. Remove the oil strainer stay.
22. Remove the oil strainer.
23. Remove the baffle plate.
24. Remove the water pipe.
25. Remove the service hole plugs using a hexagon wrench [14 mm].
26. Remove the service hole cover.
27. Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove the piston snap ring through service hole of #1 and #2 cylinders.
28. Draw out the piston pin from #1 and #2 pistons using ST. ST 499097700 PISTON PIN REMOVER NOTE: Be careful not to confuse the original combination of piston, piston pin and cylinder.
29. Similarly remove the piston pins from #3 and #4 pistons.
30. Remove the cylinder block connecting bolt on the RH side.
31. Loosen the cylinder block connecting bolt on the LH side by 2-3 turns.
32. Set the part so that the cylinder block (LH) is on the upper side, and remove the cylinder block connecting bolt.
33. Separate the cylinder block (LH) and (RH). NOTE: When separating the cylinder block, do not allow the connecting rod to fall and damage the cylinder block.
34. Remove the rear oil seal.
35. Remove the crankshaft together with connecting rod.
36. Remove the crankshaft bearings from cylinder block using a hammer handle. NOTE: Be careful not to confuse the crankshaft bearing combination. Press the bearing at the end opposite to locking lip.
37. Draw out each piston from cylinder block using wooden bar or hammer handle. NOTE: Be careful not to confuse the original combination of piston and cylinder.

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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 the cylinder block (RH).
3. Apply liquid gasket to the mating surfaces of cylinder block (RH), and position the cylinder block (LH). Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent NOTE: Do not allow liquid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc.
4. Apply a coat of engine oil to the washer and bolt thread. NOTE: Use a new seal washer.
5. Tighten the 10 mm cylinder block connecting bolts on LH side (A - D) in alphabetical sequence. Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb)
6. Tighten the 10 mm cylinder block connecting bolts on RH side (E - J) in alphabetical sequence. Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb)
7. Tighten the LH side cylinder block connecting bolts (A - D) further in alphabetical order. Tightening torque: 18 N.m (1.8 kgf-m, 13.0 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, 13.0 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, 18.1 ft-lb) (H): 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
12. Apply a coat of engine oil to the oil seal periphery, then install the rear oil seal using ST1 and ST2. NOTE: Use a new oil seal. ST1 499597100 CRANKSHAFT OIL SEAL GUIDE ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER
13. Position the top ring gap at (A) or (B) in the figure.
14. Position the second ring gap at 180° on the reverse side the top ring gap.
15. Position the upper rail gap at (C) in the figure.
16. Align the upper rail spin stopper (E) to the side hole (D) on the piston.
17. Position the expander gap at (F) in the figure on the 180° opposite direction of (C).
18. Set the lower rail gap at position (G), located 120° clockwise from (C). NOTE: Make sure ring gaps do not face the same direction. Make sure ring gaps are not within the piston skirt area.
19. Install the snap ring. Install the snap rings in the piston holes located opposite to the service holes in cylinder block before positioning pistons in cylinders. NOTE: Use new snap rings.
20. Install piston. Set the parts so that the #1 and #2 cylinders are on the upper side. Using the ST1, turn the crankshaft so that #1 and #2 connecting rods are set at bottom dead center. ST1 499987500 CRANKSHAFT SOCKET Apply a coat of engine oil to the pistons and cylinders and insert pistons in their cylinders using ST2. ST2 498747300 PISTON GUIDE NOTE: Face the piston front mark towards the front of the engine.
21. Install piston pin. Apply a coat of engine oil to ST3 before insertion, and then insert it into the service hole to align piston pin hole with connecting rod small end. ST3 499017100 PISTON PIN GUIDE Apply a coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole. Install the snap ring. NOTE: Use new snap rings. Apply liquid gasket around the service hole plug. Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent Install the service hole plug and gasket. NOTE: Use a new gasket. Set the parts so that the #3 and #4 cylinders are on the upper side. Following the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
22. Install the water pipe.
23. Install the baffle plate. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
24. Install the oil strainer to the cylinder block. NOTE: Use new O-rings. Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb)
25. Install the oil strainer stay. NOTE: Tighten the oil strainer stay together with baffle plate. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
26. Apply liquid gasket to the mating surfaces, and install the oil pan. NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1207C (Part No. 004403012) or equivalent Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
27. Apply liquid gasket to the mating surfaces 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. Liquid gasket: Mating surface THREE BOND 1217G or equivalent Bolt thread (A) (when reusing the bolt) THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
28. Install the flywheel. (MT model) INSTALLATION , Flywheel.>
29. Install the clutch disc and cover. (MT model) INSTALLATION , Clutch Disc and Cover.>
30. Install the drive plate. (AT model) To lock the crankshaft, use ST. ST 498497100 CRANKSHAFT STOPPER Tightening torque: 72 N.m (7.3 kgf-m, 52.8 ft-lb)
31. Install the oil pump. Using the ST, install the front oil seal. ST 499587100 OIL SEAL INSTALLER NOTE: Use a new oil seal. Apply liquid gasket to the matching surface of oil pump. Liquid gasket: THREE BOND 1215 (Part No. 004403007) 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. Apply liquid gasket to the three bolts thread shown in figure, (when reusing bolts) Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
32. Install the water pump and 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) NOTE: When installing the water pump, tighten bolts in two stages in alphabetical sequence as shown in the figure. Use a new gasket.
33. Install the water by-pass pipe for heater.
34. Install the oil cooler. INSTALLATION , Engine Oil Cooler.>
35. Install the oil filter. INSTALLATION , Engine Oil Filter.>
36. Install the water by-pass pipe between oil cooler and water pump.
37. Install the water pipe. NOTE: Use new O-rings.
38. Install the cylinder head. INSTALLATION, Cylinder Head.>
39. Install the oil level gauge guide and tighten the attachment bolts. (LH side) Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
40. Install the rocker cover and rocker cover gasket. NOTE: Use a new gasket.
41. Install the crank sprocket. INSTALLATION, Crank Sprocket.>
42. Install the cam sprocket. INSTALLATION, Cam Sprocket.>
43. Install the timing belt. INSTALLATION, Timing Belt.>
44. Install the timing belt cover. INSTALLATION, Timing Belt Cover.>
45. Install the crank pulley. INSTALLATION, Crank Pulley.>
46. Install the generator and A/C compressor brackets on cylinder head.
47. Install the V-belts. INSTALLATION, V-belt.>
48. Install the intake manifold. INSTALLATION , Intake Manifold.>

Scheme 372

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 373

1. Apply 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 marking side facing forward.
3. Tighten the connecting rod cap with connecting rod bolt. Make sure the arrow mark on connecting rod cap facing front during installation. NOTE: Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching number. When tightening the connecting rod nuts, 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.