Engine Mechanical (H6DO): Removal & Installation Subaru Outback BP рестайлинг

REMOVAL

1. Remove the engine unit. < Refer to «REMOVAL»(ref-306934-S18862283272008122600000) , Engine Assembly . >
2. Remove the engine mounting from engine assembly.

INSTALLATION

Install in the reverse order of removal.

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.

Scheme 506

1. Remove the collector cover.
2. Install the tool to belt tension adjuster assembly installation bolt.
3. Rotate the tool clockwise and loosen the V-belt to remove.

Install in the reverse order of removal.

Scheme 507

Scheme 508

1. Replace the V-belt, if cracks, fraying or wear is found.
2. Make sure that the V-belt automatic belt tension indicator (A) is within the range (D).

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

Scheme 509

Scheme 510

1. Remove the V-belts. < Refer to «REMOVAL»(ref-306934-S00045395632008122600000) , V-belt . >
2. Remove the crank pulley cover.
3. Remove the crank pulley bolt. To lock the crankshaft, use ST. ST 499977100 CRANK PULLEY WRENCH
4. Remove the crank pulley.

Scheme 511

1. Install the crank pulley.
2. Install the crank 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 crank pulley bolts. Tightening torque: 178 N.m (18.1 kgf-m, 131 ft-lb)
3. Install the crank pulley cover. NOTE: Use new O-rings. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
4. Install the V-belts. < Refer to «INSTALLATION»(ref-306934-S12467634492008122600000) , V-belt . >

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

Scheme 512

1. Remove the V-belts. < Refer to «REMOVAL»(ref-306934-S00045395632008122600000) , V-belt . >
2. Remove the crank pulley. < Refer to «REMOVAL»(ref-306934-S37336761242008122600000) , Crank Pulley . >
3. Remove the bolts which install oil pipe (RH) onto the front chain cover.
4. Remove the front chain cover. NOTE: Chain cover installation bolt has three different sizes. To prevent the confusion in installation, keep these bolts on container individually.

Scheme 513

Scheme 514

Scheme 515

1. Remove the used liquid gasket from mating surface, and degrease it.
2. Apply liquid gasket to the mating surface of front chain cover. NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket THREE BOND 1217G (Part No. K0877Y0100) or equivalent Applying liquid gasket diameter 2.5±0.5 mm (0.098±0.020 in)
3. Install the front chain cover. Temporarily tighten the bolts. CAUTION: Do not install the bolts in wrong place.
4. Tighten the bolts in the numerical order as shown in the figure. Tightening torque: 6.6 N.m (0.67 kgf-m, 4.8 ft-lb)
5. Tighten the bolts which install oil pipe (RH) onto the front chain cover. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
6. Install the crank pulley. < Refer to «INSTALLATION»(ref-306934-S37786717882008122600000) , Crank Pulley . >
7. Install the V-belts. < Refer to «INSTALLATION»(ref-306934-S12467634492008122600000) , V-belt . >

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

Scheme 516

Scheme 517

Scheme 518

Scheme 519

Scheme 520

Scheme 521

Scheme 522

Scheme 523

Scheme 524

Scheme 525

1. Remove the V-belts. < Refer to «REMOVAL»(ref-306934-S00045395632008122600000) , V-belt . >
2. Remove the crank pulley. < Refer to «REMOVAL»(ref-306934-S37336761242008122600000) , Crank Pulley . >
3. Remove the front chain cover. < Refer to «REMOVAL»(ref-306934-S11554534202008122600000) , Front Chain Cover . >
4. Remove the chain tensioner (RH). NOTE: Be careful not to come out the plunger (A).
5. Remove the chain guide (RH: between cams).
6. Remove the chain guide (RH).
7. Remove the chain tensioner lever (RH).
8. Remove the timing chain (RH).
9. Remove the chain tensioner (LH). NOTE: Be careful not to come out the plunger.
10. Remove the chain tensioner lever (LH).
11. Remove the chain guide (LH: between cams).
12. Remove the chain guide (LH).
13. Remove the chain guide (center).
14. Remove the idler sprocket (upper).
15. Remove the timing chain (LH).
16. Remove the idler sprocket (lower).

Note. Be careful that the foreign matter is not into or onto assembled component during installation. Apply engine oil to the chain guide, chain tensioner lever and idler sprocket when installing.

Scheme 526

Scheme 527

Scheme 528

Scheme 529

Scheme 530

Scheme 531

Scheme 532

Scheme 533

Scheme 534

Scheme 535

Scheme 536

1. Preparation for chain tensioner installation Insert the screw, spring pin and tension rod into tensioner body. While depressing the tensioner onto rubber mat, twist it to shorten tension rod. Then insert the thin pin into the hole between tension rod and tension body to keep it. NOTE: Work on the rubber mat or other anti-skid materials.
2. Using the ST, align the "Top mark" on crank sprocket to 9 o'clock position as shown in the figure ST 18252AA000 CRANKSHAFT SOCKET
3. Align the key groove on exhaust cam sprocket to 12 o'clock position as shown in the figure.
4. Align the intake cam sprocket as shown in the figure.
5. Turn the crank sprocket clockwise, align the "Top mark" to 12 o'clock position. (Piston #1 is in TDC position) NOTE: Do not rotate the crank shaft and cam sprocket before completing timing chain installation.
6. Install the idler sprocket (lower). Tightening torque: 69 N.m (7.0 kgf-m, 50.9 ft-lb)
7. Install the timing chain (LH). Align the timing mark (B) on the crank sprocket with mark (A) on the timing chain (LH). Install the timing chain (LH) to the idler sprocket (lower), water pump, exhaust cam sprocket (LH) and intake cam sprocket (LH) in this order. NOTE: Check that the mark on timing chain (A) and cam sprocket (B) is aligned as same as aligned on crank sprocket. Install the idler sprocket (upper). Tightening torque: 69 N.m (7.0 kgf-m, 50.9 ft-lb) Install the chain guide (LH: between cams). Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) NOTE: Use a new installing bolt. Install the chain guide (LH). Tightening torque: 16 N.m (1.6 kgf-m, 12 ft-lb) Install the chain tensioner lever (LH). Tightening torque: 16 N.m (1.6 kgf-m, 12 ft-lb) Install the chain tensioner (LH). Tightening torque: 16 N.m (1.6 kgf-m, 12 ft-lb)
8. Install the timing chain (RH). Align the marks of timing chain LH and RH on the idler sprocket (lower). Install the timing chain (RH) to the intake cam sprocket (RH) and exhaust cam sprocket (RH) in this order. NOTE: Check that the mark on timing chain (A) and cam sprocket (B) is aligned as same as aligned on crank sprocket. Install the chain guide (RH). Install the chain tensioner lever (RH). Tightening torque: 16 N.m (1.6 kgf-m, 12 ft-lb) Install the chain guide (RH: between cams). Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) NOTE: Use a new installing bolt. Install the chain tensioner (RH). Tightening torque: 16 N.m (1.6 kgf-m, 12 ft-lb) Adjust the clearance between chain guide (RH) and chain guide (center) within 8.4 - 8.6 mm (0.331 - 0.339 in). Install the chain guide (center). Tightening torque: 7.8 N.m (0.8 kgf-m, 5.9 ft-lb) NOTE: Use a new installing bolt. Check that each mark on the sprocket and timing chain is matched, and then draw out the stopper pin from chain tensioner.
9. Install the front chain cover. < Refer to «INSTALLATION»(ref-306934-S38941861682008122600000) , Front Chain Cover . >
10. Install the crank pulley. < Refer to «INSTALLATION»(ref-306934-S37786717882008122600000) , Crank Pulley . >
11. Install the V-belts. < Refer to «INSTALLATION»(ref-306934-S12467634492008122600000) , V-belt . >

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

Scheme 537

Scheme 538

1. Remove the V-belts. < Refer to «REMOVAL»(ref-306934-S00045395632008122600000) , V-belt . >
2. Remove the crank pulley. < Refer to «REMOVAL»(ref-306934-S37336761242008122600000) , Crank Pulley . >
3. Remove the front chain cover. < Refer to «REMOVAL»(ref-306934-S11554534202008122600000) , Front Chain Cover . >
4. Remove the timing chain assembly. < Refer to «REMOVAL»(ref-306934-S20844672542008122600000) , Timing Chain Assembly . >
5. Remove the cam sprocket. To lock the camshaft, use the ST. ST 499977500 CAM SPROCKET WRENCH ST 18231AA020 CAM SPROCKET WRENCH

1. Install the cam sprocket. To lock the camshaft, use the ST. Tightening torque: 29.5 N.m (3.0 kgf-m, 21.8 ft-lb)
2. Further tighten the bolt. Tightening angle: Intake side 45°±5° Exhaust side 25°±5° ST 499977500 CAM SPROCKET WRENCH ST 18231AA020 CAM SPROCKET WRENCH
3. Install the timing chain assembly. < Refer to «INSTALLATION»(ref-306934-S10773092172008122600000) , Timing Chain Assembly . >
4. Install the front chain cover. < Refer to «INSTALLATION»(ref-306934-S38941861682008122600000) , Front Chain Cover . >
5. Install the crank pulley. < Refer to «INSTALLATION»(ref-306934-S37786717882008122600000) , Crank Pulley . >
6. Install the V-belts. < Refer to «INSTALLATION»(ref-306934-S12467634492008122600000) , V-belt . >

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

Scheme 539

1. Remove the V-belts. < Refer to «REMOVAL»(ref-306934-S00045395632008122600000) , V-belt . >
2. Remove the crank pulley. < Refer to «REMOVAL»(ref-306934-S37336761242008122600000) , Crank Pulley . >
3. Remove the front chain cover. < Refer to «REMOVAL»(ref-306934-S11554534202008122600000) , Front Chain Cover . >
4. Remove the timing chain assembly. < Refer to «REMOVAL»(ref-306934-S20844672542008122600000) , Timing Chain Assembly . >
5. Remove the crank sprocket (A).

1. Install the crank sprocket (A).
2. Install the timing chain assembly. < Refer to «INSTALLATION»(ref-306934-S10773092172008122600000) , Timing Chain Assembly . >
3. Install the front chain cover. < Refer to «INSTALLATION»(ref-306934-S38941861682008122600000) , Front Chain Cover . >
4. Install the crank pulley. < Refer to «INSTALLATION»(ref-306934-S37786717882008122600000) , Crank Pulley . >
5. Install the V-belts. < Refer to «INSTALLATION»(ref-306934-S12467634492008122600000) , V-belt . >

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

Scheme 540

1. Remove the V-belts. < Refer to «REMOVAL»(ref-306934-S00045395632008122600000) , V-belt . >
2. Remove the crank pulley. < Refer to «REMOVAL»(ref-306934-S37336761242008122600000) , Crank Pulley . >
3. Remove the front chain cover. < Refer to «REMOVAL»(ref-306934-S11554534202008122600000) , Front Chain Cover . >
4. Remove the timing chain. < Refer to «REMOVAL»(ref-306934-S20844672542008122600000) , Timing Chain Assembly . >
5. Remove the cam sprocket. < Refer to «REMOVAL»(ref-306934-S37343707272008122600000) , Cam Sprocket . >
6. Remove the crank sprocket. < Refer to «REMOVAL»(ref-306934-S07218733582008122600000) , Crank Sprocket . >
7. Remove the oil pump. < Refer to «REMOVAL»(ref-306936-S05398537902008122600000) , Oil Pump . >
8. Remove the water pump. < Refer to «REMOVAL»(ref-306920-S12658800322008122600000) , Water Pump . >
9. Remove the rear chain cover. NOTE: Installation bolt has seven different sizes. To prevent the confusion in installation, keep these bolts on container individually.

Note. When replacing the rear chain cover, suitable size cover must be selected. < Refer to INSPECTION , Oil Pump . >

Scheme 541

Scheme 542

Scheme 543

Scheme 544

1. Remove the used liquid gasket from mating surface, and degrease it.
2. Apply liquid gasket to the mating surface of rear chain cover. NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket THREE BOND 1217G (Part No. K0877Y0100) or equivalent Applying liquid gasket diameter (A) 1.0±0.5 mm (0.039±0.020 in) (B) 3.0±1.0 mm (0.118±0.039 in)
3. Install the O-ring. NOTE: Use new O-rings. Do not install the O-ring in wrong place.
4. Install the water pump gasket. NOTE: Use a new gasket.
5. Temporarily tighten the rear chain cover. NOTE: Do not install the bolts in wrong place.
6. Tighten the bolts in the numerical order as shown in the figure. Tightening torque: TIGHTENING TORQUE (1) - (11) 9 N.m (0.9 kgf-m, 6.5 ft-lb) (12) - (19) 20 N.m (2.0 kgf-m, 14.8 ft-lb) (20) - (30) 9 N.m (0.9 kgf-m, 6.5 ft-lb) (31) - (38) 12 N.m (1.2 kgf-m, 8.7 ft-lb) (39) - (45) 9 N.m (0.9 kgf-m, 6.5 ft-lb)
7. Install the water pump. < Refer to «INSTALLATION»(ref-306920-S13897836372008122600000) , Water Pump . >
8. Install the oil pump. < Refer to «INSTALLATION»(ref-306936-S26986842552008122600000) , Oil Pump . >
9. Install the crank sprocket. < Refer to «INSTALLATION»(ref-306934-S22875159142008122600000) , Crank Sprocket . >
10. Install the cam sprocket. < Refer to «INSTALLATION»(ref-306934-S00106019382008122600000) , Cam Sprocket . >
11. Install the timing chain. < Refer to «INSTALLATION»(ref-306934-S10773092172008122600000) , Timing Chain Assembly . >
12. Install the front chain cover. < Refer to «INSTALLATION»(ref-306934-S38941861682008122600000) , Front Chain Cover . >
13. Install the crank pulley. < Refer to «INSTALLATION»(ref-306934-S37786717882008122600000) , Crank Pulley . >
14. Install the V-belts. < Refer to «INSTALLATION»(ref-306934-S12467634492008122600000) , V-belt . >

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

Scheme 545

Scheme 546

Scheme 547

Scheme 548

1. Remove the V-belts. < Refer to «REMOVAL»(ref-306934-S00045395632008122600000) , V-belt . >
2. Remove the crank pulley. < Refer to «REMOVAL»(ref-306934-S37336761242008122600000) , Crank Pulley . >
3. Remove the front chain cover. < Refer to «REMOVAL»(ref-306934-S11554534202008122600000) , Front Chain Cover . >
4. Remove the timing chain assembly. < Refer to «REMOVAL»(ref-306934-S20844672542008122600000) , Timing Chain Assembly . >
5. Remove the cam sprocket. < Refer to «REMOVAL»(ref-306934-S37343707272008122600000) , Cam Sprocket . >
6. Remove the crank sprocket. < Refer to «REMOVAL»(ref-306934-S07218733582008122600000) , Crank Sprocket . >
7. Remove the rear chain cover. < Refer to «REMOVAL»(ref-306934-S17773334382008122600000) , Rear Chain Cover . >
8. Disconnect the oil pipe.
9. Remove the rocket cover (LH).
10. Remove the plugs (LH).
11. Loosen the camshaft cap bolts equally, a little at a time in alphabetical sequence shown in the figure.
12. Remove the camshaft caps and camshaft (LH). NOTE: Arrange camshaft caps in order so that they can be installed in their original positions.
13. Similarly, remove the camshafts (RH) and related parts.

Scheme 549

Scheme 550

Scheme 551

Scheme 552

Scheme 553

Scheme 554

Scheme 555

1. Apply engine oil to camshaft journals, and install the camshaft.
2. Install the camshaft cap. Apply liquid gasket sparingly to back side of front camshaft cap as shown in the figure. CAUTION: Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to flow toward cam journal, resulting in engine seizure. NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Applying liquid gasket diameter: 2.0±0.5 mm (0.079±0.020 in) Apply engine oil to cap bearing surface, and install the cap to camshaft. Tighten the rocker cover bolts in the numerical order as shown in the figure. Tightening torque: (1) - (12): 16 N.m (1.6 kgf-m, 12 ft-lb) (13) - (16):9.75 N.m (1.0 kgf-m, 7.2 ft-lb)
3. Install the plugs. Tightening torque: 60 N.m (6.1 kgf-m, 44 ft-lb)
4. Install the rocker cover. Install the rocker cover gasket to the rocker cover. NOTE: Use a new rocker cover gasket. Apply liquid gasket sparingly to the mating surface of cylinder head and rocker cover as shown in the figure. CAUTION: Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to flow toward cam journal, resulting in engine seizure. NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent LH side RH side Tighten the rocker cover bolts in the numerical order as shown in the figure. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) LH side RH side
5. Connect the oil pipe. NOTE: Be careful not to mistake the location of (A) and (B). Use a new gasket. Tightening torque: (A), (B) 29 N.m (3.0 kgf-m, 21.4 ft-lb) (C) 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
6. Install the rear chain cover. < Refer to «INSTALLATION»(ref-306934-S42814844102008122600000) , Rear Chain Cover . >
7. Install the crank sprocket. < Refer to «INSTALLATION»(ref-306934-S22875159142008122600000) , Crank Sprocket . >
8. Install the cam sprocket. < Refer to «INSTALLATION»(ref-306934-S00106019382008122600000) , Cam Sprocket . >
9. Install the timing chain assembly. < Refer to «INSTALLATION»(ref-306934-S10773092172008122600000) , Timing Chain Assembly . >
10. Install the front chain cover. < Refer to «INSTALLATION»(ref-306934-S38941861682008122600000) , Front Chain Cover . >
11. Install the crank pulley. < Refer to «INSTALLATION»(ref-306934-S37786717882008122600000) , Crank Pulley . >
12. Install the V-belts. < Refer to «INSTALLATION»(ref-306934-S12467634492008122600000) , V-belt . >

Scheme 556

Scheme 557

Scheme 558

1. Measure the bend of camshaft. Repair or replace if bended.
2. Check the journal for damage and wear. Replace if faulty.
3. Check the cutout portion used for camshaft sensor for damage. Replace if faulty.
4. Measure the outside diameter of camshaft journal. If the journal diameter is not within specification, check the oil clearance. CAMSHAFT JOURNAL SPECIFICATIONS Camshaft journal Front Except for front Standard mm (in) 37.946 - 37.963 (1.4939 - 1.4946) 25.946 - 25.963 (1.0215 - 1.0222)
5. Measurement of the camshaft journal oil clearance: Clean the bearing caps and camshaft journals. Place the camshafts on cylinder head. (Without installing the valve rocker.) Place a plastigauge across each camshaft journals. Install the bearing cap. NOTE: Do not turn the camshaft. 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.
6. 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 HIGH 42.09 - 42.19 mm (1.6571 - 1.6610 in) LOW1 38.14 - 38.24 mm (1.5016 - 1.5055 in) LOW2 38.14 - 38.24 mm (1.5016 - 1.5055 in) Exhaust 40.45 - 40.55 mm (1.5925 - 1.5965 in) Cam base circle diameter A: Intake HIGH 32.0 mm (1.2598 in) LOW1 31.84 mm (1.2535 in) LOW2 31.84 mm (1.2535 in) Exhaust 32.0 mm (1.2598 in)
7. Measure the side clearance of the camshaft with a dial gauge. If the side clearance exceeds the standard or there is offset wear, replace the caps and cylinder head as a set. If necessary replace the camshaft. Standard Intake 0.075 - 0.135 mm (0.0030 - 0.0053 in) Exhaust 0.030 - 0.090 mm (0.0012 - 0.0035 in)

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

Scheme 559

1. Remove the V-belts. < Refer to «REMOVAL»(ref-306934-S00045395632008122600000) , V-belt . >
2. Remove the crank pulley. < Refer to «REMOVAL»(ref-306934-S37336761242008122600000) , Crank Pulley . >
3. Remove the front chain cover. < Refer to «REMOVAL»(ref-306934-S11554534202008122600000) , Front Chain Cover . >
4. Remove the timing chain assembly. < Refer to «REMOVAL»(ref-306934-S20844672542008122600000) , Timing Chain Assembly . >
5. Remove the cam sprocket. < Refer to «REMOVAL»(ref-306934-S37343707272008122600000) , Cam Sprocket . >
6. Remove the crank sprocket. < Refer to «REMOVAL»(ref-306934-S07218733582008122600000) , Crank Sprocket . >
7. Remove the rear chain cover. < Refer to «REMOVAL»(ref-306934-S17773334382008122600000) , Rear Chain Cover . >
8. Remove the camshaft. < Refer to «REMOVAL»(ref-306934-S05185704882008122600000) , Camshaft . >
9. Remove the cylinder head bolts in the numerical order as shown in the figure.
10. Leave bolts (2) and (4) 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.
12. Remove the bolts (2) and (4) to remove cylinder head.
13. Remove the cylinder head gasket. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block.
14. Similarly, remove the cylinder head (RH).

Scheme 560

1. Install the cylinder head and gaskets on cylinder block. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block. NOTE: Use a new cylinder head gasket.
2. Tighten the cylinder head bolts. Apply a coat of engine oil to washers and cylinder head bolt threads. Install the cylinder head to cylinder block, and then tighten the bolts with torque of 20 N.m (2.0 kgf-m, 14.8 ft-lb) in numerical sequence as shown in the figure. Tighten the bolts with torque of 50 N.m (5.1 kgf-m, 36.9 ft-lb) in numerical sequence as shown in the figure. Loosen all the bolts by 180° in reverse order of installation, and loosen again by 180°. Tighten the bolts with torque of 20 N.m (2.0 kgf-m, 14.8 ft-lb) in numerical sequence as shown in the figure. Tighten the bolts (1) - (4) with torque of 48 N.m (4.9 kgf-m, 35.4 ft-lb) in numerical sequence. Tighten the bolts (5) - (8) with torque of 44 N.m (4.5 kgf-m, 32.5 ft-lb) in numerical sequence. Tighten all bolts 90° in the numerical order as shown in the figure. Tighten the bolt (1) - (4) by 45° in the numerical order.
3. Install the camshaft. < Refer to «INSTALLATION»(ref-306934-S17233981792008122600000) , Camshaft . >
4. Install the rear chain cover. < Refer to «INSTALLATION»(ref-306934-S42814844102008122600000) , Rear Chain Cover . >
5. Install the crank sprocket. < Refer to «INSTALLATION»(ref-306934-S22875159142008122600000) , Crank Sprocket . >
6. Install the cam sprocket. < Refer to «INSTALLATION»(ref-306934-S00106019382008122600000) , Cam Sprocket . >
7. Install the timing chain assembly. < Refer to «INSTALLATION»(ref-306934-S10773092172008122600000) , Timing Chain Assembly . >
8. Install the front chain cover. < Refer to «INSTALLATION»(ref-306934-S38941861682008122600000) , Front Chain Cover . >
9. Install the crank pulley. < Refer to «INSTALLATION»(ref-306934-S37786717882008122600000) , Crank Pulley . >
10. Install the V-belts. < Refer to «INSTALLATION»(ref-306934-S12467634492008122600000) , V-belt . >

Scheme 561

1. Set the cylinder head on ST. ST 18250AA010 CYLINDER HEAD TABLE
2. Remove the valve lifter.
3. Set the ST on valve spring retainer. Compress the valve spring and remove the valve spring retainer key. Remove each valve and valve spring. ST 499718000 VALVE SPRING REMOVER NOTE: Mark each valve to prevent confusion. 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 562

1. Installation of valve spring and valve: Set the cylinder head on ST. ST 18250AA010 CYLINDER HEAD TABLE 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. Install the valve spring and retainer. NOTE: Be sure to install the valve spring with its close-coiled end facing the seat on cylinder head. For the valve spring on intake side, install two of them (inner and outer). Install the valve spring with the painted side facing to retainer. Set the ST on valve spring. ST 499718000 VALVE SPRING REMOVER Compress the valve spring and fit the valve spring retainer key. After installing, tap the valve spring retainers lightly with a plastic hammer for better seating.
2. Apply oil to the surface of valve lifter and valve shim.
3. Install the valve lifter and valve shim.

Scheme 563

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. Set the cylinder head on ST. ST 18250AA010 CYLINDER HEAD TABLE
3. Measure the flatness of the cylinder head surface that mates with cylinder block using a straight edge (A) and thickness gauge (B). Flatness: Standard 0.02 mm (0.0008 in) Standard height of cylinder head: 124±0.05 mm (4.88±0.0020 in) NOTE: Uneven torque for the cylinder head bolts can cause warping. When reinstalling, pay special attention to the torque so as to tighten evenly.

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

Scheme 564

Scheme 565

Scheme 566

Scheme 567

Scheme 568

Scheme 569

Scheme 570

Scheme 571

Scheme 572

Scheme 573

1. Remove the V-belts. < Refer to «REMOVAL»(ref-306934-S00045395632008122600000) , V-belt . >
2. Remove the crank pulley. < Refer to «REMOVAL»(ref-306934-S37336761242008122600000) , Crank Pulley . >
3. Remove the front chain cover. < Refer to «REMOVAL»(ref-306934-S11554534202008122600000) , Front Chain Cover . >
4. Remove the timing chain assembly. < Refer to «REMOVAL»(ref-306934-S20844672542008122600000) , Timing Chain Assembly . >
5. Remove the cam sprocket. < Refer to «REMOVAL»(ref-306934-S37343707272008122600000) , Cam Sprocket . >
6. Remove the crank sprocket. < Refer to «REMOVAL»(ref-306934-S07218733582008122600000) , Crank Sprocket . >
7. Remove the rear chain cover. < Refer to «REMOVAL»(ref-306934-S17773334382008122600000) , Rear Chain Cover . >
8. Remove the camshaft. < Refer to «REMOVAL»(ref-306934-S05185704882008122600000) , Camshaft . >
9. Remove the cylinder head. < Refer to «REMOVAL»(ref-306934-S23588750542008122600000) , Cylinder Head . >
10. Remove the drive plate using the ST. ST 498497100 CRANKSHAFT STOPPER
11. Remove the crankshaft position sensor plate.
12. Remove the crankshaft position sensor bracket.
13. Rotate the engine to set oil pan upper.
14. Remove the bolts which secure oil pan lower to oil pan upper.
15. 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.
16. Remove the oil strainer.
17. Remove the bolts which install oil pan upper onto cylinder block. NOTE: Installation bolt has five different sizes. To prevent the confusion in installation, keep these bolts on container individually.
18. Remove the service hole cover and service hole plugs using a hexagon wrench.
19. Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then, using the ST, remove the piston snap ring through service hole of #1 and #2 cylinders. ST 18233AA000 PISTON PIN SNAP RING PLIERS
20. 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.
21. Similarly remove the piston pins from #3, #4, #5, and #6 pistons.
22. Remove the cylinder block connecting bolts.
23. 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.
24. Remove the rear oil seal.
25. Remove the crankshaft together with connecting rod.
26. 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.
27. 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.

Scheme 574

Scheme 575

Scheme 576

Scheme 577

Scheme 578

Scheme 579

Scheme 580

Scheme 581

Scheme 582

Scheme 583

Scheme 584

Scheme 585

Scheme 586

Scheme 587

Scheme 588

Scheme 589

1. After setting the cylinder block to ST, install the crankshaft bearing. ST 18232AA000 ENGINE STAND NOTE: 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 on the cylinder block (RH).
3. Apply liquid gasket to the mating surfaces of cylinder block (RH), and position the cylinder block (LH). NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent NOTE: Do not allow liquid gasket to run over to oil passages, bearing grooves, etc. Applying liquid gasket diameter: 1.0±0.2 mm (0.039±0.008 in)
4. Apply a coat of engine oil to the washer and bolt thread.
5. Tighten all bolts in the numerical order as shown in the figure. Tightening torque: (1) - (11), (13): 25 N.m (2.5 kgf-m, 18.4 ft-lb) (12), (14): 20 N.m (2.0 kgf-m, 14.8 ft-lb)
6. Retighten all bolts in the numerical order as shown in the figure. Tightening torque: (1) - (11), (13): 25 N.m (2.5 kgf-m, 18.4 ft-lb) (12), (14): 20 N.m (2.0 kgf-m, 14.8 ft-lb)
7. Tighten all bolts 90° - 110° in the numerical order as shown in the figure.
8. Install the upper bolt to cylinder block. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb) NOTE: After tightening the cylinder block connecting bolts, remove the liquid gasket which is running over to the sealing surface for rear chain cover and oil pan upper.
9. 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 rear oil seal. ST1 499597100 CRANKSHAFT OIL SEAL GUIDE ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER
10. Position the top ring gap at (A) in the figure.
11. Position the second ring gap at (B).
12. Position the upper rail gap at (C) in the figure.
13. Position the expander gap at (D) in the figure.
14. Position the lower rail gap at (E) in the figure. CAUTION: Make sure ring gaps do not face the same direction. Make sure ring gaps are not within the piston skirt area. Assemble it so that R mark faces to top side of piston.
15. Install the snap ring. Install the snap rings in the piston holes located opposite to the service holes in cylinder block when positioning all pistons in corresponding cylinders. NOTE: Use new snap rings.
16. Installing piston: Using the ST1, turn the crankshaft so that #3 and #4 connecting rod small ends are set on the service hole (A). ST1 18252AA000 CRANKSHAFT SOCKET Apply a thin coat of engine oil to piston and cylinder. Using the ST2, press-fit the piston into cylinder. ST2 18254AA000 PISTON GUIDE NOTE: Let the piston front mark (A) face towards the front of engine.
17. Installing 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 18253AA000 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. Using the ST4, install the snap ring. ST4 18233AA000 PISTON PIN SNAP RING PLIERS NOTE: Use new snap rings. Similarly install the #1, #2, #5 and #6 pistons.
18. Install the service hole plug and O-ring. NOTE: Use new O-rings.
19. Apply liquid gasket to the mating surface of oil pan upper. NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Applying liquid gasket diameter: Full line part 3.0±1.0 mm (0.12+0.04 in) Broken line part 1.0 mm (0.04 in) NOTE: Use new O-rings.
20. Temporarily tighten the oil pan upper. NOTE: Do not install the bolts in wrong place.
21. Tighten the oil pan upper installing bolts in the numerical order as shown in the figure. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
22. Install the oil strainer. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) NOTE: Use new O-rings.
23. Apply liquid gasket to the matching surface of oil pan lower. NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Applying liquid gasket diameter: 5.0±1.0 mm (0.20±0.04 in)
24. Tighten the oil pan lower installing bolts in the numerical order as shown in the figure. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
25. Install the crankshaft position sensor holder. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
26. Install the crankshaft sensor plate.
27. Using the ST, install the drive plate. ST 498497100 CRANKSHAFT STOPPER Tightening torque: 81 N.m (8.3 kgf-m, 60 ft-lb)
28. Install the cylinder head. < Refer to «INSTALLATION»(ref-306934-S13049245182008122600000) , Cylinder Head . >
29. Install the camshaft. < Refer to «INSTALLATION»(ref-306934-S17233981792008122600000) , Camshaft . >
30. Install the rear chain cover. < Refer to «INSTALLATION»(ref-306934-S42814844102008122600000) , Rear Chain Cover . >
31. Install the crank sprocket. < Refer to «INSTALLATION»(ref-306934-S22875159142008122600000) , Crank Sprocket . >
32. Install the cam sprocket. < Refer to «INSTALLATION»(ref-306934-S00106019382008122600000) , Cam Sprocket . >
33. Install the timing chain assembly. < Refer to «INSTALLATION»(ref-306934-S10773092172008122600000) , Timing Chain Assembly . >
34. Install the front chain cover. < Refer to «INSTALLATION»(ref-306934-S38941861682008122600000) , Front Chain Cover . >
35. Install the crank pulley. < Refer to «INSTALLATION»(ref-306934-S37786717882008122600000) , Crank Pulley . >
36. Install the V-belts. < Refer to «INSTALLATION»(ref-306934-S12467634492008122600000) , V-belt . >

Scheme 590

1. Remove the connecting rod cap.
2. Remove the connecting rod bearing. NOTE: Arrange the removed connecting rod, connecting rod cap and bearing in order, to prevent confusion.
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 591

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

T: 53 (5.4, 39)

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. Install the connecting rod cap. Make sure the arrow mark on connecting rod cap facing front during installation. CAUTION: Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching number. When tightening the connecting rod bolts, apply oil on the threads and flange end. Tightening torque: 53 N.m (5.4 kgf-m, 39 ft-lb)
4. Install the oil ring spacer, upper rail and lower rail by hand.
5. Install the second ring and top ring using piston ring expander.

Oil flow control solenoid valve is a unit with camshaft cap. Refer to "Camshaft" for removal procedure. < Refer to REMOVAL , Camshaft . >

Install in the reverse order of removal.

Scheme 592

Scheme 593

1. Disconnect the ground cable from battery.
2. Remove the air intake chamber. < Refer to «REMOVAL»(ref-306919-S12426210742008122600000) , Air Intake Chamber . >
3. Disconnect the connector from the oil switching solenoid valve.
4. Remove the oil switching solenoid valve.
5. Remove the variable valve lift diagnosis oil pressure switch. < Refer to «REMOVAL»(ref-306918-S05671972112008122600000) , Variable Valve Lift Diagnosis Oil Pressure Switch . >
6. Remove the oil temperature sensor. < Refer to «REMOVAL»(ref-306918-S36029220562008122600000) , Oil Temperature Sensor . >
7. Remove the oil switching solenoid valve holder from the cylinder head.

Scheme 594

1. Install the oil switching solenoid valve holder. NOTE: Use a new gasket. Temporarily tighten the bolts by tightening torque of 5 - 10 N.m (0.5 - 1.0 kgf-m, 3.7 - 7.4 ft-lb) in order shown in the figure. Tighten the bolts by tightening torque of 10±0.5 N.m (1.0±0.05 kgf-m, 7.4±0.37 ft-lb) in order shown in the figure.
2. Install the oil temperature sensor. < Refer to «INSTALLATION»(ref-306918-S34516024742008122600000) , Oil Temperature Sensor . >
3. Install the variable valve lift diagnosis oil pressure switch. < Refer to «INSTALLATION»(ref-306918-S27613935032008122600000) , Variable Valve Lift Diagnosis Oil Pressure Switch . >
4. Install the oil switching solenoid valve.
5. Connect the connector to oil switching solenoid valve.
6. Install the air intake chamber. < Refer to «INSTALLATION»(ref-306919-S31904316202008122600000) , Air Intake Chamber . >
7. Connect the battery ground cable to the battery.