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Engine Mechanical (H6DO): Other Subaru Outback BP рестайлинг

Mechanical 45 illustrations ~5074 words

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. All removed parts, if to be reused, should be reinstalled in the original positions and directions.
  12. Bolts, nuts and washers should be replaced with new parts as required.
  13. Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks.
  14. Remove or install the engine in an area where chain hoists, lifting devices, etc. are available for ready use.
  15. 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.
  16. Prior to starting work, prepare the following: Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc.
  17. Lift up or lower the vehicle when necessary. Make sure to support the correct positions.

GENERAL TOOL

TOOL NAMEREMARKS
Compression gaugeUsed for measuring compression.
Vacuum gaugeUsed for measuring intake manifold vacuum.
Oil pressure gaugeUsed for measuring engine oil pressure.
Fuel pressure gaugeUsed for measuring fuel pressure.

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 chain
  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. Read the ignition timing using Subaru Select Monitor. < Refer to «READ CURRENT DATA FOR ENGINE (NORMAL MODE)»(ref-306932-S03496141862008122600000) , OPERATION, Subaru Select Monitor . > Ignition timing [BTDC/RPM]: 15°±8°/650 If the timing is not correct, check the ignition control system. Refer to "Engine Control System". < Refer to «BASIC DIAGNOSTIC PROCEDURE»(ref-306932-S25592065892008122600000) . >

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 cleaner case. < Refer to «REMOVAL»(ref-306919-S29381940832008122600000) , Air Cleaner Case . >
  5. Connect the timing light to the power wire of #1 ignition coil.
  6. Install the air cleaner case. < Refer to «INSTALLATION»(ref-306919-S00160647592008122600000) , Air Cleaner Case . >
  7. 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]: 15°±8°/650 If the timing is not correct, check the ignition control system. Refer to "Engine Control System". < Refer to «BASIC DIAGNOSTIC PROCEDURE»(ref-306932-S25592065892008122600000) . >

Scheme 608

Scheme 608: INSPECTION
Scheme 608: INSPECTION
  1. Warm-up the engine.
  2. Disconnect the brake vacuum hose from the intake manifold, and install the vacuum gauge.
  3. Keep the engine at idle speed and read the vacuum gauge indication. By observing the vacuum gauge needle movement, internal condition of the engine can be diagnosed as described below. Vacuum pressure (at idling, A/C OFF): Less than -60.0 kPa (-450 mmHg, --17.72 inHg) VACUUM PRESSURE 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. Air leakage around intake manifold gasket, disconnection or damage of 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

INTAKE SIDE

Note. Adjustment of valve clearance should be performed while engine is cold. Do not wear gloves during removal and installation of valve lifter. Do not use valve lifters that were dropped or otherwise exposed to strong impacts. When installing the valve lifter, align the anti-rotation of valve lifter with groove on cylinder head, and insert the valve lifter.

  1. Measure all the valve clearances. < Refer to «INSPECTION»(ref-306934-S36553329582008122600000) , Valve Clearance . > NOTE: Record each valve clearance after measurement.
  2. Remove the camshaft. < Refer to «REMOVAL»(ref-306934-S05185704882008122600000) , Camshaft . >
  3. Remove the valve lifter.
  4. Remove the shim from valve lifter.
  5. Check the thickness of the shim from the markings on the side of the shim that was removed.
  6. Select a shim of suitable thickness from the following table using the measured valve clearance and shim thickness. SHIM THICKNESS CHART Unit: mm (in) S = (V + T) - 0.20 (0.0079) S: Required shim thickness V: Measured valve clearance T: Shim thickness to be used SHIM THICKNESS CHART Part No. Thickness mm (in) 13218AK890 1.92 (0.0756) 13218AK900 1.94 (0.0764) 13218AK910 1.96 (0.0772) 13218AK920 1.98 (0.0780) 13218AK930 2.00 (0.0787) 13218AK940 2.02 (0.0795) 13218AK950 2.04 (0.0803) 13218AK960 2.06 (0.0811) 13218AK970 2.07 (0.0815) 13218AK980 2.08 (0.0819) 13218AK990 2.09 (0.0823) 13218AL000 2.10 (0.0827) 13218AL010 2.11 (0.0831) 13218AL020 2.12 (0.0835) 13218AL030 2.13 (0.0839) 13218AL040 2.14 (0.0843) 13218AL050 2.15 (0.0846) 13218AL060 2.16 (0.0850) 13218AL070 2.17 (0.0854) 13218AL080 2.18 (0.0858) 13218AL090 2.19 (0.0862) 13218AL100 2.20 (0.0866) 13218AL110 2.21 (0.0870) 13218AL120 2.22 (0.0874) 13218AL130 2.23 (0.0878) 13218AL140 2.24 (0.0882) 13218AL150 2.25 (0.0886) 13218AL160 2.26 (0.0890) 13218AL170 2.27 (0.0894) 13218AL180 2.28 (0.0898) 13218AL190 2.29 (0.0902) 13218AL200 2.30 (0.0906) 13218AL210 2.31 (0.0909) 13218AL220 2.32 (0.0913) 13218AL230 2.33 (0.0917) 13218AL240 2.34 (0.0921) 13218AL250 2.35 (0.0925) 13218AL260 2.36 (0.0929) 13218AL270 2.37 (0.0933) 13218AL280 2.38 (0.0937) 13218AL290 2.39 (0.0941) 13218AL300 2.40 (0.0945) 13218AL310 2.41 (0.0949) 13218AL320 2.42 (0.0953) 13218AL330 2.43 (0.0957) 13218AL340 2.44 (0.0961) 13218AL350 2.45 (0.0965) 13218AL360 2.46 (0.0969) 13218AL370 2.47 (0.0972) 13218AL380 2.48 (0.0976) 13218AL390 2.49 (0.0980) 13218AL400 2.50 (0.0984) 13218AL410 2.51 (0.0988) 13218AL420 2.52 (0.0992) 13218AL430 2.53 (0.0996) 13218AL440 2.54 (0.1000) 13218AL450 2.55 (0.1004) 13218AL460 2.56 (0.1008) 13218AL470 2.57 (0.1012) 13218AL480 2.58 (0.1016) 13218AL490 2.59 (0.1020) 13218AL500 2.60 (0.1024) 13218AL510 2.61 (0.1028) 13218AL520 2.62 (0.1032) 13218AL530 2.64 (0.1039) 13218AL540 2.66 (0.1047) 13218AL550 2.68 (0.1055) 13218AL560 2.70 (0.1063) 13218AL570 2.72 (0.1071) 13218AL580 2.74 (0.1079) 13218AL590 2.76 (0.1087)

EXHAUST SIDE

Note. Adjustment of valve clearance should be performed while engine is cold. Do not wear gloves during removal and installation of valve lifter. Do not use valve lifters that were dropped or otherwise exposed to strong impacts.

Scheme 609

Scheme 609: EXHAUST SIDE
Scheme 609: EXHAUST SIDE
  1. Measure all the valve clearances. < Refer to «INSPECTION»(ref-306934-S36553329582008122600000) , Valve Clearance . > NOTE: Record each valve clearance after measurement.
  2. Remove the camshaft. < Refer to «REMOVAL»(ref-306934-S05185704882008122600000) , Camshaft . >
  3. Remove the valve lifter.
  4. Measure the thickness of valve lifter using micrometer.
  5. Select a valve lifter of suitable thickness from the following table using the measured valve clearance and valve lifter thickness. VALVE LIFTER THICKNESS CHART Unit: mm (in) S = (V + T) - 0.35 (0.0138) S: Valve lifter thickness required V: Measured valve clearance T: Valve lifter thickness to be used VALVE LIFTER THICKNESS CHART Part No. Thickness mm (in) 13228AD181 4.32 (0.1701) 13228AD191 4.34 (0.1709) 13228AD201 4.36 (0.1717) 13228AD211 4.38 (0.1724) 13228AD221 4.40 (0.1732) 13228AD231 4.42 (0.1740) 13228AD241 4.44 (0.1748) 13228AD251 4.46 (0.1756) 13228AD261 4.48 (0.1764) 13228AD271 4.50 (0.1772) 13228AD281 4.52 (0.1780) 13228AD291 4.54 (0.1787) 13228AD301 4.56 (0.1795) 13228AD311 4.58 (0.1803) 13228AD321 4.60 (0.1811) 13228AC581 4.62 (0.1819) 13228AC591 4.63 (0.1823) 13228AC601 4.64 (0.1827) 13228AC611 4.65 (0.1831) 13228AC621 4.66 (0.1835) 13228AC631 4.67 (0.1839) 13228AC641 4.68 (0.1843) 13228AC651 4.69 (0.1846) 13228AC661 4.70 (0.1850) 13228AC671 4.71 (0.1854) 13228AC681 4.72 (0.1858) 13228AC691 4.73 (0.1862) 13228AC701 4.74 (0.1866) 13228AC711 4.75 (0.1870) 13228AC721 4.76 (0.1874) 13228AC731 4.77 (0.1878) 13228AC741 4.78 (0.1882) 13228AC751 4.79 (0.1886) 13228AC761 4.80 (0.1890) 13228AC771 4.81 (0.1894) 13228AC781 4.82 (0.1898) 13228AC791 4.83 (0.1902) 13228AC801 4.84 (0.1906) 13228AC811 4.85 (0.1909) 13228AC821 4.86 (0.1913) 13228AC831 4.87 (0.1917) 13228AC841 4.88 (0.1921) 13228AC851 4.89 (0.1925) 13228AC861 4.90 (0.1929) 13228AC871 4.91 (0.1933) 13228AC881 4.92 (0.1937) 13228AC891 4.93 (0.1941) 13228AC901 4.94 (0.1945) 13228AC911 4.95 (0.1949) 13228AC921 4.96 (0.1953) 13228AC931 4.97 (0.1957) 13228AC941 4.98 (0.1961) 13228AC951 4.99 (0.1965) 13228AC961 5.00 (0.1969) 13228AC971 5.01 (0.1972) 13228AC981 5.02 (0.1976) 13228AC991 5.03 (0.1980) 13228AD001 5.04 (0.1984) 13228AD011 5.05 (0.1988) 13228AD021 5.06 (0.1992) 13228AD031 5.07 (0.1996) 13228AD041 5.08 (0.2000) 13228AD051 5.09 (0.2004) 13228AD061 5.10 (0.2008) 13228AD071 5.11 (0.2012) 13228AD081 5.12 (0.2016) 13228AD091 5.13 (0.2020) 13228AD101 5.14 (0.2024) 13228AD111 5.15 (0.2028) 13228AD121 5.16 (0.2032) 13228AD131 5.17 (0.2035) 13228AD141 5.18 (0.2039) 13228AD151 5.19 (0.2043) 13228AD161 5.20 (0.2047) 13228AD171 5.21 (0.2051) 13228AD331 5.23 (0.2059) 13228AD341 5.25 (0.2067) 13228AD351 5.27 (0.2075) 13228AD361 5.29 (0.2083) 13228AD371 5.31 (0.2091) 13228AD381 5.33 (0.2098) 13228AD391 5.35 (0.2106) 13228AD401 5.37 (0.2114) 13228AD411 5.39 (0.2122) 13228AD421 5.41 (0.2130) 13228AD431 5.43 (0.2138) 13228AD441 5.45 (0.2146) 13228AD451 5.47 (0.2154) 13228AD461 5.49 (0.2161) 13228AD471 5.51 (0.2169) 13228AD481 5.53 (0.2177) 13228AD491 5.55 (0.2185) 13228AD501 5.57 (0.2193) 13228AD511 5.59 (0.2201)

Scheme 610

Scheme 610: REMOVAL
Scheme 610: REMOVAL

Scheme 611

Scheme 611
Scheme 611

Scheme 612

Scheme 612
Scheme 612

Scheme 613

Scheme 613
Scheme 613

Scheme 614

Scheme 614
Scheme 614

Scheme 615

Scheme 615
Scheme 615

Scheme 616

Scheme 616
Scheme 616

Scheme 617

Scheme 617
Scheme 617

Scheme 618

Scheme 618
Scheme 618

Scheme 619

Scheme 619
Scheme 619

Scheme 620

Scheme 620
Scheme 620

Scheme 621

Scheme 621
Scheme 621

Scheme 622

Scheme 622
Scheme 622

Scheme 623

Scheme 623
Scheme 623
  1. Set the vehicle on a lift.
  2. Open the front hood fully and support with the front hood stay.
  3. Remove the collector cover.
  4. Collect the refrigerant from the A/C system. < Refer to «PROCEDURE»(ref-303059-S27666449362008102300000) , Refrigerant Recovery Procedure . >
  5. Release the fuel pressure. < Refer to «RELEASING OF FUEL PRESSURE»(ref-306918-S13194033592008122600000) , PROCEDURE, Fuel . >
  6. Remove the fuel filler cap.
  7. Remove the battery from vehicle.
  8. Remove the air intake duct, air cleaner case and air intake chamber. < Refer to «REMOVAL»(ref-306919-S32466810272008122600000) , Air Intake Duct . > < Refer to «REMOVAL»(ref-306919-S29381940832008122600000) , Air Cleaner Case . > < Refer to «REMOVAL»(ref-306919-S12426210742008122600000) , Air Intake Chamber . >
  9. Remove the radiator from vehicle. < Refer to «REMOVAL»(ref-306920-S39423910222008122600000) , Radiator . >
  10. Remove the V-belts. < Refer to «REMOVAL»(ref-306934-S00045395632008122600000) , V-belt . >
  11. Disconnect the A/C pressure hoses from the A/C compressor. < Refer to «REMOVAL»(ref-303059-S31339104882008102300000) , Hose and Tube . >
  12. Remove the engine ground terminal.
  13. Disconnect the following connector. Engine harness connectors Generator connector and terminal A/C compressor connector Power steering switch connector
  14. Disconnect the following hoses. Brake booster vacuum hose Heater inlet and outlet hoses Pressure regulator vacuum hose
  15. Remove the power steering pump together with the bracket. NOTE: Do not disconnect the hose and pipe from the pump body.
  16. Place the power steering pump on the right side wheel apron.
  17. Lift up the vehicle.
  18. Remove the under cover.
  19. Remove the front exhaust pipe. < Refer to «REMOVAL»(ref-306933-S01649836562008122600000) , Front Exhaust Pipe . > NOTE: Be careful not to let the front exhaust pipe interfere with water pipes on engine side.
  20. Remove the ground cable.
  21. Remove the bolts and nuts which hold lower side of transmission to engine.
  22. Remove the nuts which install front cushion rubber onto front crossmember.
  23. Separate the torque converter clutch from drive plate. Lower the vehicle. Remove the service hole plug (A). Remove the bolts which hold torque converter clutch to drive plate. Remove other bolts while rotating the crankshaft using socket wrench.
  24. Remove the pitching stopper.
  25. Disconnect the fuel delivery hose and evaporation hose. CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth. Disconnect the connector of fuel pipe by pushing the ST in the direction of arrow. ST 42099AE000 CONNECTOR REMOVER Remove the clip, and disconnect the evaporation hose from the pipe.
  26. Support the engine with a lifting device and wire ropes.
  27. Support the transmission with a garage jack. CAUTION: Doing this is very important to prevent the transmission from lowering due to its own weight. CAUTION: Before removing the engine away from transmission, check to be sure no work has been overlooked.
  28. Separation of engine and transmission: Remove the starter. < Refer to (H4SO) «REMOVAL»(ref-303063-S37914115652008102300000) , Starter. > Remove the bolts which hold upper side of transmission to engine.
  29. Attach the ST to the converter case. ST 498277200 STOPPER SET
  30. Remove the engine from vehicle. Slightly raise the engine. Raise the transmission with garage jack. Slowly move the engine away from engine compartment. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc. 31) Remove the front cushion rubbers.

Scheme 624

Scheme 624
Scheme 624

Scheme 625

Scheme 625
Scheme 625

Scheme 626

Scheme 626
Scheme 626

Scheme 627

Scheme 627
Scheme 627
  1. Install the front cushion rubbers. Tightening torque: 35 N.m (3.6 kgf-m, 25.8 ft-lb)
  2. Position the engine in engine compartment and align it with transmission. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
  3. Tighten the bolts which hold upper side of transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
  4. Remove the lifting device and wire ropes.
  5. Remove the garage jack.
  6. Install the pitching stopper. Tightening torque: T1. 50 N.m (5.1 kgf-m, 36.9 ft-lb) T2: 58 N.m (5.9 kgf-m, 42.8 ft-lb)
  7. Remove the ST from converter case. NOTE: Be careful not to drop the ST into the converter case when removing the ST. ST 498277200 STOPPER SET
  8. < Refer to (H4SO) «INSTALLATION»(ref-303063-S01454615632008102300000) , Starter. >
  9. Install the torque converter clutch to drive plate. Tighten the bolts which hold torque converter clutch to drive plate. Tighten other bolts while rotating the crankshaft using socket wrench. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb) Install the service hole plug (A) to prevent getting foreign matter inside.
  10. Install the power steering pump. Tightening torque: (A) 25 N.m (2.5 kgf-m, 18.4 ft-lb) (B): 33 N.m (3.4 kgf-m, 24.3 ft-lb)
  11. Lift up the vehicle.
  12. Tighten the bolts and nuts which hold lower side of the transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
  13. Tighten the nuts which install the front cushion rubber onto crossmember. Tightening torque: 85 N.m (8.7 kgf-m, 62.7 ft-lb) NOTE: Make sure the front cushion rubber mounting bolts (A) and locator (B) are securely installed.
  14. Install the front exhaust pipe. < Refer to «INSTALLATION»(ref-306933-S39797609462008122600000) , Front Exhaust Pipe . > NOTE: Be care not to let the front exhaust pipe interfere with water pipes and crossmember on engine side. Be care not to scratch the flange surface of front exhaust pipe with stud bolt on engine.
  15. Connect the ground cable.
  16. Install the under cover.
  17. Lower the vehicle.
  18. Connect the following hoses. Fuel delivery hose and evaporation hose Heater inlet and outlet hoses Brake booster vacuum hose Pressure regulator vacuum hose
  19. Connect the following connectors. Engine harness connectors Generator connector and terminal A/C compressor connector Power steering switch connector
  20. Install the engine ground terminals. Tightening torque: 14 N.m (1.4 kgf-m, 10.1 ft-lb)
  21. Install the A/C pressure hoses. < Refer to «INSTALLATION»(ref-303059-S29579663662008102300000) , Hose and Tube . >
  22. Install the V-belts. < Refer to «INSTALLATION»(ref-306934-S12467634492008122600000) , V-belt . >
  23. Install the radiator to vehicle. < Refer to «INSTALLATION»(ref-306920-S40689228772008122600000) , Radiator . >
  24. Install the air intake duct, air cleaner case and air intake chamber. < Refer to «INSTALLATION»(ref-306919-S05184785282008122600000) , Air Intake Duct . > < Refer to «INSTALLATION»(ref-306919-S00160647592008122600000) , Air Cleaner Case . > < Refer to «INSTALLATION»(ref-306919-S31904316202008122600000) , Air Intake Chamber . >
  25. Install the battery in the vehicle, and connect cables.
  26. Fill engine coolant. < Refer to «FILLING OF ENGINE COOLANT»(ref-306920-S34383935342008122600000) , REPLACEMENT, Engine Coolant . >
  27. Check the ATF level and replenish it if necessary. < Refer to «INSPECTION»(ref-306924-S39179730662008122600000) , Automatic Transmission Fluid . >
  28. Charge the A/C system with refrigerant. < Refer to «PROCEDURE»(ref-303059-S04769971162008102300000) , Refrigerant Charging Procedure . >
  29. Install the collector cover.
  30. Remove the front hood stay, and close the front hood.
  31. Lower the vehicle from the lift.

VALVE SEAT

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

Valve seat width W

Standard

Intake

1.0 mm (0.039 in)

Exhaust

1.5 mm (0.059 in)

Scheme 628

Scheme 628: VALVE SEAT
Scheme 628: VALVE SEAT

Scheme 629

Scheme 629: VALVE GUIDE
Scheme 629: VALVE GUIDE

Scheme 630

Scheme 630
Scheme 630

Scheme 631

Scheme 631
Scheme 631
  1. Check the clearance between valve guide and stem. The clearance can be checked by measuring the valve stem outer diameter with a micrometer and valve guide inner diameter with a caliper gauge respectively. 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 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: 5.500 - 5.512 mm (0.2165 - 0.2170 in) Valve stem outer diameters: Intake 5.455 - 5.470 mm (0.2148 - 0.2154 in) Exhaust 5.445 - 5.460 mm (0.2144 - 0.2150 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 18250AA010 CYLINDER HEAD TABLE ST2 499765700 VALVE GUIDE REMOVER Turn the cylinder head upside down and place the ST as shown in the figure. ST 18251AA040 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 the cylinder head, and insert the ST1 into valve guide. Press in until the valve guide upper end is flush with the upper surface of ST2. ST1 499765700 VALVE GUIDE REMOVER ST2 18251AA040 VALVE GUIDE ADJUSTER Check the valve guide protrusion. Valve guide protrusion L: 11.4 - 11.8 mm (0.449 - 0.465 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. ST 499765900 VALVE GUIDE REAMER 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.

Scheme 632

Scheme 632: INTAKE AND EXHAUST VALVE
Scheme 632: INTAKE AND EXHAUST VALVE
  1. Inspect the flange and stem of the valve, and replace if damaged, worn, or deformed, or if "H" is outside of the standard. Head edge thickness H: Standard Intake (A) 1.0 mm (0.039 in) Exhaust (B) 1.2 mm (0.047 in)
  2. Put a small amount of grinding compound on the seat surface, and lap the valve and valve seat. Install a new 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 99.7 mm (3.925 in) Exhaust 105.2 mm (4.142 in)

Scheme 633

Scheme 633: VALVE SPRING
Scheme 633: VALVE SPRING
  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. VALVE SPRING SPECIFICATIONS Free length mm (in) Intake Inner 39.55 (1.5571) Outer 41.18 (1.6213) Exhaust 46.32 (1.8236) Squareness Intake Inner 2.5°, 1.7 mm (0.067 in) or less Outer 2.5°, 1.8 mm (0.071 in) or less Exhaust 2.5°, 2.0 mm (0.079 in) or less
  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.

Scheme 634

Scheme 634: INTAKE AND EXHAUST VALVE OIL SEAL
Scheme 634: INTAKE AND EXHAUST VALVE OIL SEAL
  1. For the following, replace the oil seal with a new part. 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. Set the cylinder head on ST1.
  3. Using the ST2, press in the oil seal. ST1 18250AA010 CYLINDER HEAD TABLE ST2 499585500 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 to strike in.

Scheme 635

Scheme 635: VALVE LIFTER
Scheme 635: VALVE LIFTER

Scheme 636

Scheme 636
Scheme 636
  1. Check the valve lifter visually.
  2. Measure the outer diameter of valve lifter. Outer diameter: 32.959 - 32.975 mm (1.2976 - 1.2982 in)
  3. Measure the inner diameter of valve lifter hole of cylinder head. Inner diameter: 32.994 - 33.016 mm (1.2990 - 1.2998 in) NOTE: If difference between outer diameter of valve lifter and inner diameter of valve lifter hole is out of the standard or offset wearing is emitted, 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 cylinder block surface that mates with cylinder head for warping by using a straight edge. Standard height of cylinder block: 202 mm (7.95 in)

Scheme 637

Scheme 637: CYLINDER AND PISTON
Scheme 637: CYLINDER AND PISTON

Scheme 638

Scheme 638
Scheme 638

Scheme 639

Scheme 639
Scheme 639
  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: 89.205 - 89.215 mm (3.5120 - 3.5124 in) B: 89.195 - 89.205 mm (3.5116 - 3.5120 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 heights as shown in the figure, using a cylinder bore gauge. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Cylindrically: Standard 0.030 mm (0.0012 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. How to measure the outer diameter of each piston: 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: 37.3 mm (1.4685 in) Piston outer diameter: Standard A: 89.205 - 89.215 mm (3.5120 - 3.5124 in) B: 89.195 - 89.205 mm (3.5116 - 3.5120 in) 0.25 mm (0.0098 in) oversize 89.445 - 89.465 mm (3.5215 - 3.5222 in) 0.50 mm (0.0197 in) oversize 89.695 - 89.715 mm (3.5313 - 3.5321 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 (-0.0004 - 0.0004 in)
  6. Boring and honing: If the value of cylindrically, out-of-round-ness, or cylinder-to-piston clearance measured is out of standard or if there is any damage on the cylinder wall, rebore it to use an oversize piston. CAUTION: When any of the cylinders needs reboring, 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. Cylinder inner diameter boring limit (diameter): To 89.715 mm (3.5321 in) 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.

Scheme 640

Scheme 640: PISTON AND PISTON PIN
Scheme 640: PISTON AND PISTON PIN

Scheme 641

Scheme 641
Scheme 641

Scheme 642

Scheme 642
Scheme 642
  1. Check the piston and piston pin for breaks, cracks or wear. Replace if faulty.
  2. Check the piston ring groove for wear or 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.

Scheme 643

Scheme 643: PISTON RING
Scheme 643: PISTON RING

Scheme 644

Scheme 644
Scheme 644

Scheme 645

Scheme 645
Scheme 645
  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 on the piston, be careful of the direction of each rail.
  2. Squarely place the piston ring and oil ring in cylinder, and measure the piston ring gap with a thickness gauge. PISTON RING GAP CHART Standard mm (in) Piston ring gap Top ring 0.20 - 0.35 (0.0079 - 0.0138) Second ring 0.35 - 0.50 (0.0138 - 0.0197) Oil ring 0.20 - 0.60 (0.0079 - 0.0236)
  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 GROOVE SPECIFICATIONS 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) Clearance between oil ring and oil ring groove 0.045 - 0.125 (0.0018 - 0.0049)

Scheme 646

Scheme 646: CONNECTING ROD
Scheme 646: CONNECTING ROD

Scheme 647

Scheme 647
Scheme 647

Scheme 648

Scheme 648
Scheme 648

Scheme 649

Scheme 649
Scheme 649
  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 it has the bend or twist.
  3. Install the connecting rod fitted with bearing to crankshaft and measure the thrust clearance. 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 undersize as necessary. (See the table below.) Connecting rod oil clearance: Standard 0.016 - 0.043 mm (0.0006 - 0.0017 in) CONNECTING ROD OIL CLEARANCE Unit: mm (in) Bearing Bearing size (Thickness at center) Outer diameter of crank pin Standard 1.490 - 1.506 (0.0587 - 0.0593) 51.984 - 52.000 (2.0466 - 2.0472) 0.03 (0.0012) undersize 1.509-1.513 (0.0594 - 0.0596) 51.954 - 51.970 (2.0454 - 2.0461) 0.05 (0.0020) undersize 1.519-1.523 (0.0598 - 0.0600) 51.934-51.950 (2.0446 - 2.0453) 0.25 (0.0098) undersize 1.619 - 1.623 (0.0637 - 0.0639) 51.734 - 51.750 (2.0368 - 2.0374)
  6. Inspect the bushing at connecting rod small end, and replace 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 ST after applying oil on the periphery of bushing. ST 18350AA000 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.

Scheme 650

Scheme 650: CRANKSHAFT AND CRANKSHAFT BEARING
Scheme 650: CRANKSHAFT AND CRANKSHAFT BEARING

Scheme 651

Scheme 651
Scheme 651

Scheme 652

Scheme 652
Scheme 652
  1. Clean the crankshaft completely, and check it for cracks using liquid penetrant tester. Replace if defective.
  2. Check the crankshaft for bend, and repair or replace if needed. Repair or replace if bended. NOTE: If a suitable V-block is not available, install #1 and #5 crankshaft bearing on cylinder block, position the crankshaft on these bearings, and then check the crankshaft bend using a dial gauge.
  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 readjust 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 and crank journal: Out-of-roundness 0.005 mm (0.0002 in) Cylindrically 0.006 mm (0.0002 in) CRANK JOURNAL DIAMETER Unit: mm (in) Crank journal diameter Crank pin outer diameter #1,#3, #5, #7 #2, #4, #6 Standard Journal O.D. 63.992 - 64.008 (2.5194 - 2.5200) 51.984 - 52.000 (2.0466 - 2.0472) Bearing size (Thickness at center) 1.992 - 2.005 (0.0784 - 0.0789) 1.996 - 2.009 (0.0786 - 0.0791) 1.490 - 1.506 (0.0587 - 0.0593) 0.03 (0.0012) undersize Journal O.D. 63.962 - 63.978 (2.5182 - 2.5188) 51.954 - 51.970 (2.0454 - 2.0461) Bearing size (Thickness at center) 2.011 - 2.014 (0.0792 - 0.0793) 2.015 - 2.018 (0.0793 - 0.0794) 1.509 - 1.513 (0.0594 - 0.0596) 0.05 (0.0020) undersize Journal O.D. 63.942 - 63.958 (2.5174 - 2.5180) 51.934 - 51.950 (2.0446 - 2.0453) Bearing size (Thickness at center) 2.021 - 2.024 (0.0796 - 0.0797) 2.025 - 2.028 (0.0797 - 0.0798) 1.519 - 1.523 (0.0598 - 0.0600) 0.25 (0.0098) undersize Journal O.D. 63.742 - 63.758 (2.5095 - 2.5102) 51.734 - 51.750 (2.0368 - 2.0374) Bearing size (Thickness at center) 2.121 - 2.124 (0.0835 - 0.0836) 2.125 - 2.128 (0.0837 - 0.0838) 1.619-1.623 (0.0637 - 0.0639)
  4. Measure the thrust clearance of crankshaft at center bearing by using thickness gauge. If the thrust clearance is not within 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 recondition the crankshaft as necessary. Crankshaft oil clearance: Standard 0.010 - 0.030 mm (0.0004 - 0.0012 in)

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